TruDisk Laser Operating Manual PDF

Operator's manual
TruDisk 3000, TruDisk 3001,

TruDisk 6002, TruDisk 6006
(FD27)
Supplement to documentation
Safe combination of laser device,

laser light cable and focusing
optics
Supplement to documen-
tation
Safe combination of laser

device, laser light cable and
focusing optics
Order Information Please specify when ordering this document:
Supplement to documentation
Safe combination of laser device, laser light cable and focus-
ing optics
Edition 2018-03
Document number 22-24-83-00-EN02
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: info@de.trumpf-laser.com
TRUMPF Laser GmbH

Address for service Technischer Kundendienst
D-78713 Schramberg
Fon: +49 7156 303 - 37 444
Fax: +49 7422 515 - 148
E-Mail: service.tls@de.trumpf.com
E-Mail: spareparts.tls@de.trumpf.com
© TRUMPF Laser GmbH

Before you proceed ...
Not all combinations of laser device, laser light cable and focus-
ing optics are safe. Personal injury and damage to property can
occur if laser device, laser light cable and focusing optics do not
match with one another.
This document provides users with answers to the following
questions:
■ What are the characteristics of a safe combination of laser
light cable, laser device and focusing optics?
■ Which dangers arise from impermissible combinations of
laser device, laser light cable and focusing optics?
■ Where can I find information on what is need to evaluate the
combination?
22-24-83-00-EN02 Before you proceed ... I

II Before you proceed ... 22-24-83-00-EN02
Table of contents
1 Characteristics of safe combinations 2
2 Dangers due to impermissible combinations 3

2.1 Numerical apertures cannot be combined 3
2.2 Wavelength spectrums do not match 3
2.3 Focusing optics is not designed for the rated 4
power of the laser device
2.4 Laser light cable or focusing optics are not 4
from TRUMPF Laser GmbH
3 Information required to assess the safety of 5

a combination
4 Examples of safe combinations 8
22-24-83-00-EN02 Table of contents 1

1. Characteristics of safe combinations
A combination of laser device, laser light cable and focusing

optics is safe when the following criteria are fulfilled:
Wavelength Laser device, laser light cable and focusing optics must be
designed for the same wavelength spectrum.
Rated output Laser light cable and focusing optics must be suitable for the
rated power of the laser device.
Numerical aperture The numerical aperture of the laser light cable and the focusing
optics must not be smaller than that of the laser device.
Laser device Optical laser cable Focusing optics

Wavelength = LLK / focusing optics = Laser device / focusing optics = Laser device / LLK
Rated output ≤ Laser light cable ≥ Laser device ≥ Laser device
Numerical ≤ Laser light cable ≥ Laser device, ≤ focusing optics ≥ Laser light cable
aperture
Tab. 1
2 Characteristics of safe combinations 22-24-83-00-EN02

2. Dangers due to impermissible
combinations
Laser radiation escaping

DANGER
Laser radiation can damage skin and eyes. Damage to
eyesight or even complete blindness can result.
Ø Only use safe combinations of laser device, laser light cable
and focusing optics.
Housing of focusing optics gets hot

DANGER
Touching the focusing optics can lead to serious burns.
Ø Only use safe combinations of laser device, laser light cable
and focusing optics.
2.1 Numerical apertures cannot be

combined
Numerical aperture of the If the numerical aperture of the focusing optics is smaller than
focusing optics is too small the numerical aperture on the decoupling connector, a part of the
laser light hits the aperture of the focusing optics. The housing
of the focusing optics can heat up strongly as a result
(> 300° C). The following dangers result from this:
■ Fire hazard: Materials in the environment of the focusing
optics can catch fire.
■ Risk of burns: People who work with the focusing optics
may suffer burns.
■ Risks from escape of laser radiation: People in the envi-
ronment of the focusing optics may be injured by escaping
laser radiation. Skin burns and loss of eyesight are possible.
Numerical aperture of the If the numerical aperture of the incoupling connector of the laser
laser light cable is too small light cable is smaller than the numerical aperture of the laser
device, a part of the laser light is coupled into the connector of
the laser light cable. This results in increased scattered light.
The laser devices switches off automatically.
2.2 Wavelength spectrums do not match
Focusing optics is not Focusing optics are designed for defined wavelength spectrums.
designed for laser device If a focusing optics is operated with a different wavelength than
specified, unforeseen reflections and transmissions to optical
22-24-83-00-EN02 Dangers due to impermissible combinations 3

components may occur. The housing of the focusing optics can
heat up strongly as a result (> 300° C). The following dangers
result from this:
may suffer burns.
■ Risks of laser radiation in eyepiece and stereo micro-
scope: People who look into the eyepiece or the stereomi-
croscope during the processing operation can lose their eye-
sight.
2.3 Focusing optics is not designed for

the rated power of the laser device
Rated power of the laser A focusing optics will be damaged if it is operated with a higher
device is too high power than that which is specified. The housing of the focusing
optics can hereby heat up strongly (> 300° C). The following
dangers result from this:
may suffer burns.
2.4 Laser light cable or focusing optics

are not from TRUMPF Laser GmbH
Unknown risks When the laser device is combined with components that are not
from TRUMPF Laser GmbH, the integrator or the operator must
draw up a risk assessment for the combined machine. This risk
assessment must include risks that could occur through the com-
bination of the individual components.
4 Dangers due to impermissible combinations 22-24-83-00-EN02

3. Information required to assess the
safety of a combination
Information on the laser Information on the numerical aperture and on the wavelength
device spectrum is available either in the user's compartment or on the
incoupling optics.
Information in the user's compartment (example TruDisk Fig. 1

FD17)
Information on the incoupling optics (example TruDisk FD27) Fig. 2
Information on the laser Information on the permissible wavelength spectrum and the per-
light cable (examples) missible numerical aperture are to be indicated on the incoupling
connector and on the outcoupling connector. The nameplate con-
tains additional information about the laser light cable.
1 Designation 5 Green border = LLK for green laser

2 Document number/Index light
3 Serial number 6 Numerical aperture
4 Material number 7 Permissible spectrum of wave-
lengths
Information on laser light cables (examples) Fig. 3
22-24-83-00-EN02 Information required to assess the safety of a 5

combination
Information on LLK-D NA01 (green) Fig. 4
Information on LLK-D 100/400 µm NA01 double-core Fig. 5
Depending on the light laser cable, the information on the incou-

pling connector can deviate from that on the outcoupling connec-
tor.
1 Information on the incoupling 2 Information on the outcoupling

connector connector
Information on LLK-D NA0067/015-01 HP Fig. 6
Information on the focusing The processing optics contains information on power, numerical
optics aperture and wavelength spectrum on the plug receptacle.
Information on processing optics (example) Fig. 7
6 Information required to assess the safety of a 22-24-83-00-EN02

combination
The housing of a programmable focusing optics contains infor-
mation on power, numerical aperture and wavelength spectrum.
Information on programmable focusing optics (example PFO Fig. 8

33)
Information on programmable focusing optics (example Fig. 9

PFO-3D)
22-24-83-00-EN02 Information required to assess the safety of a 7

combination
4. Examples of safe combinations
The following laser devices, laser light cables and focusing

optics may be combined with one another (examples):
Laser device Optical laser cable Focusing optics

TruDisk 4001 (FD27) LLK-D 01/04 SPL DC Processing optics (BEO)
TruDisk Pulse (FP04) LLK-D 01 SPL GNC Processing optics (BEO)
(green)
TruDisk 4002 (FD17) LLK-D 02 SPL Programmable focusing optics (PFO)
TruDisk 10001 (FD25) LLK-D NA0067/015-01 SPL HP Processing optics (BEO HP)
Examples of safe combinations of laser device, laser light cable and focusing optics Tab. 2
8 Examples of safe combinations 22-24-83-00-EN02

Operator's manual

TruDisk 6002, TruDisk 6006
(FD27)
Original operator's manual
Edition 2018-04
Order Information Please specify when ordering this document:
Operator's manual
TruDisk 3000, TruDisk 3001, TruDisk 3002, TruDisk 3006,
TruDisk 6002, TruDisk 6006 (FD27)
Edition 2018-04
Document number 20-10-06-A3001-CR02
TRUMPF Laser GmbH

Address for orders Vertrieb
78713 Schramberg
Fon: +49 7422 515 - 0
Fax: +49 7422 515 - 436
E-Mail: info@de.trumpf-laser.com
TRUMPF Laser GmbH

Address for service Technischer Kundendienst
D-78713 Schramberg
Fon: +49 7156 303 - 37 444
Fax: +49 7422 515 - 148
E-Mail: service.tls@de.trumpf.com
E-Mail: spareparts.tls@de.trumpf.com
© TRUMPF Laser GmbH

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

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

regional regulations regarding accident prevention, especially
laser safety, and environmental protection.
Target group of the These operating instructions regarding the laser product are
operating instructions intended for persons who are entrusted with working on the laser
product, for example with:
■ Transport
■ Operation
■ Maintenance
Further documentation Documents mentioned as reference are part of the delivery of

the laser product:
■ Installation instructions
■ Interface descriptions
■ Software manual
20-10-06-A3001-
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2018-04 Before you proceed ... I
II Before you proceed ... 2018-04 20-10-06-A3001-
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Table of contents
Chapter 1 Safety
Safety is important 1‐3
1 Overview 1‐4
2 Warning instructions 1‐5
3 Terms 1‐6
4 Hazards 1‐9
4.1 Laser light 1‐9
4.2 Electric energy 1‐10
4.3 Gases, aerosols, dusts 1‐11
4.4 Thermal energy 1‐12
Fire, explosion 1‐12
Temperature of the workpiece 1‐12
4.5 Noise 1‐12
5 Safety of the laser product 1‐14

5.1 Laser beam emission openings 1‐14
5.2 EMERGENCY STOP push-button (option) 1‐15
5.3 Safety circuits 1‐16
5.4 Laser warning lamp 1‐18
5.5 Key-operated switch 1‐18
5.6 Labels and warning signs 1‐19
Required signs 1‐19
Labels on the laser device 1‐22
Label in the area of the focusing optics 1‐24
6 Measures of the user 1‐25

6.1 Designated use of the laser product 1‐25
6.2 Technical measures 1‐25
6.3 Organizational measures 1‐26
6.4 Observing standards and regulations 1‐27
6.5 Behavior in certain operating stages 1‐27
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2018-04 Table of contents 0‐1
6.6 Behavior in case of emergency 1‐28
6.7 Selecting and qualifying personnel 1‐28
6.8 Instructing the personnel 1‐29
6.9 Wearing personal protective equipment 1‐30
6.10 Disposal 1‐30
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
2.2 Free space for service work 2‐8
2.3 Panel computer (option) 2‐8
2.4 Laser light cable 2‐9
2.5 Focusing optics 2‐9
3 Weight, floor at the installation site 2‐12
4 Connections: 2‐13
4.1 External connections 2‐13
4.2 Electrical interfaces 2‐14
5 Connected loads 2‐17

5.1 Electrical connection 2‐18
5.2 Electromagnetic compatibility 2‐20
5.3 Insulation resistance 2‐20
6 Cooling unit 2‐22

6.1 External cooling circuit TruDisk 3000, Tru- 2‐22
Disk 3001, TruDisk 3002, TruDisk 3006
Cooling water consumption for pipe dimen- 2‐23
sioning
0‐2 Table of contents 2018-04 20-10-06-A3001-

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sioning
Disk 5002, TruDisk 5006
sioning
sioning
6.5 "Extended ambient conditions" option 2‐34
Determining dimensioning data 2‐35
6.6 Cooling water connections 2‐37
6.7 Data for chillers 2‐37
6.8 Laser cooling circuit 2‐39
7 Ambient conditions 2‐40
8 Emissions 2‐42
9 Operator’s stand 2‐43

9.1 Location for switching the laser device on and 2‐43
off
9.2 Location for laser device operation 2‐43
9.3 Location for adjustment of the focusing optics 2‐44
9.4 Location for maintenance work 2‐45
10 Measures to be taken on delivery of the 2‐46

laser device
10.1 Delivery of the laser device 2‐46
10.2 Start-up 2‐46
11 Transport 2‐47
11.1 Transport by means of pallet jack 2‐47
11.2 Transporting by fork lift 2‐49
11.3 Moving the laser device on wheels 2‐52
11.4 Packing the laser device 2‐54
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Chapter 3 Description
1 Overview 3‐3
2 Laser 3‐5
2.1 Structure 3‐5
2.2 Specifications 3‐5
3 Optical arrangement 3‐8

3.1 Components of the optical arrangement 3‐11
Shutter switch 3‐11
Shutter switch (VW1, VW2, ...) with pilot 3‐12
laser
Deflection (U1, U2, ...) 3‐15
3.2 Selecting a light path 3‐15
3.3 Wedge beam switch (option) 3‐17
3.4 Switch can be adjusted by motor for BrightLine 3‐18
Weld (option)
3.5 Incoupling optics 3‐20
Incoupling optics LLK-D 3‐21
Laser light cable 3‐21

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4 Diode power supply 3‐26
5 Control 3‐28
6 Mains distribution 3‐30
7 Laser cooler 3‐32
8 Cabinet cooler 3‐34
9 Recirculating air dryer system (RDS) 3‐35
10 Panel computer (option) 3‐37
11 Telepresence 3‐38
11.1 Connection via VPN TRUMPF to the laser 3‐38
device
11.2 Connection via VPN laser device to TRUMPF 3‐39
11.3 Connection via SSH 3‐39
Chapter 4 Operating
1 Operation and display elements 4‐3

1.1 Housing 4‐3
1.2 PC with Windows and software TruControl 4‐5
Module Remote
1.3 Computer panel (option) 4‐5
2 Switching the laser device on and off 4‐6

2.1 Switching on at the case with switches 4‐6
2.2 Switching on with panel computer or Windows 4‐7
PC
2.3 Switching off in case of emergency or malfunc- 4‐8
tion
2.4 Switching on after E-STOP 4‐8
2.5 Switching off at the case with switches 4‐8
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2.6 Switching off after work completion with the 4‐9
panel computer or the Windows PC
3 Operating a laser device using TruCon- 4‐11

trol 1000
3.1 Responding to messages 4‐11
Resetting the message 4‐12
Select the light path in the parameter set 4‐12
Changing the light path name 4‐14
3.3 Activating and deactivating the laser 4‐15
Switching the laser on and off 4‐15
3.4 Creating pulse shapes 4‐16
3.5 Creating laser programs 4‐17
3.6 Editing light paths 4‐17
3.7 Pilot laser 4‐18
Switching the switching functions of pilot 4‐18
laser on and off
Setting the pilot laser mode 4‐19
Switching the pilot laser on and off in the 4‐21
light path
4 Controlling the laser device from outside 4‐24

4.1 TRUMPF LaserNetwork (option) 4‐24
Chapter 5 Maintenance
1 General notes 5‐3
2 Material 5‐4
2.1 Cooling water additives 5‐4
2.2 Tools and additional equipment 5‐4
Blow-out device 5‐6
2.3 Consumables 5‐7
2.4 Disposal 5‐7
3 Opening and closing the laser device 5‐8

3.1 Opening and closing doors 5‐8
3.2 Removing covers 5‐8

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3.3 Open and close hood 5‐9
4 Hose connections 5‐10

4.1 Connecting the hose 5‐10
4.2 Disconnecting the hose 5‐10
5 Operating mode 5‐11

5.1 Activating the operating mode TRUMPF main- 5‐11
tenance
6 Laser light cable 5‐14

6.1 Dismounting and mounting the laser light cable 5‐14
Removing LLK-D 5‐14
Mounting the LLK-D 5‐22
6.2 Maintaining laser light cable 5‐30
Replacing the protective sleeve with protec- 5‐30
tive glass at the LLK-D
7 Diode power supply (DPS) 5‐34

7.1 Replacing the diode power supply (DPS) 5‐35

8.1 Filling the cooling unit 5‐43
8.2 Emptying the cooling unit 5‐48
8.3 Cleaning the contamination filter 5‐67
8.4 Replacing filter element in the fine filter 5‐71
8.5 Cleaning the laser circuit 5‐73
Carrying out cleaning cycle and cooling 5‐75
water replacement
8.6 Refill the cooling water 5‐87
8.7 Checking the tightness of cooling unit 5‐89
9 Electrics 5‐91
9.1 Identifying blown electrical fuses 5‐91
9.2 Replacing the microfuse 5‐93
9.3 Activating the power circuit breaker 5‐94
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Chapter 6 What to do 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 Malfunction 6‐5
4 Dealing with messages 6‐7

4.1 Message structure 6‐7
4.2 History of messages 6‐9
Displaying the history of messages 6‐9
Setting the message filter 6‐9
Searching for a message 6‐10
Type of message 6‐12

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Chapter 1
Safety
Safety is important 1‐3
1 Overview 1‐4
2 Warning instructions 1‐5
3 Terms 1‐6
4 Hazards 1‐9
4.1 Laser light 1‐9
4.2 Electric energy 1‐10
4.3 Gases, aerosols, dusts 1‐11
4.4 Thermal energy 1‐12
Fire, explosion 1‐12
Temperature of the workpiece 1‐12
4.5 Noise 1‐12
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2018-04 Safety 1‐1
5 Safety of the laser product 1‐14
5.1 Laser beam emission openings 1‐14
5.2 EMERGENCY STOP push-button (option) 1‐15
5.3 Safety circuits 1‐16
5.4 Laser warning lamp 1‐18
5.5 Key-operated switch 1‐18
5.6 Labels and warning signs 1‐19
Required signs 1‐19
Labels on the laser device 1‐22
Label in the area of the focusing optics 1‐24
6 Measures of the user 1‐25

6.1 Designated use of the laser product 1‐25
6.2 Technical measures 1‐25
6.3 Organizational measures 1‐26
6.4 Observing standards and regulations 1‐27
6.5 Behavior in certain operating stages 1‐27
6.6 Behavior in case of emergency 1‐28
6.7 Selecting and qualifying personnel 1‐28
6.8 Instructing the personnel 1‐29
6.9 Wearing personal protective equipment 1‐30
6.10 Disposal 1‐30
1‐2 Safety 2018-04 20-10-06-A3001-

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Safety is important
This chapter contains important notes for operating your laser
product safely. Carefully read this information before starting to
operate the laser product.
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2018-04 Safety 1‐3
1. Overview
This chapter summarizes all information that you should know in

order to operate your laser product safely.
Here you will find:

■ Information about risks involved in using the laser product
■ A description of devices and measures that we, as the man-
ufacturer, have already implemented and taken to allow you
to safely use the laser product.
■ Any instructions that you, the user, must observe and put
into practice to safely operate the laser product in your work
environment and to protect the health of persons.
In other chapters of these operating instructions, you will find
descriptions and instructions for an efficient use of the laser
product. If the actions involve any risks, warning instructions pre-
cede the instructions to warn against possible consequences.
This manual must always be at hand at the place where the
laser product is used.
1‐4 Overview 2018-04 20-10-06-A3001-

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2. 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:
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 your eyes.
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!
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2018-04 Warning instructions 1‐5
3. Terms
Laser product Laser products include devices, systems or components used for
generating, transmitting and using laser light.
TRUMPF products summarized under the term "laser product"

include:
■ Lasers (beam sources)
■ Laser machines
■ Laser workstations
■ Laser devices
■ Laser light cables
■ Focusing optics
Laser light Laser light is electromagnetic radiation with wavelengths from

100 nm to 1 mm produced as the result of controlled stimulated
emission.
Laser is an acronym, short for: Light Amplification by Stimulated
Emission of Radiation.
Laser The term "Laser" summarizes all components directly used for
generating laser light:
■ Resonator, comprising rear mirror and output coupling mirror
■ Laser material
■ Pump source
Other components of lasers might include:

■ Modulators
■ Q-switch
■ Converter for generating other wavelengths
With certain forms of lasers, the components mentioned above
can be integrated as structures in a basic material.
Examples:
Rear mirror and output coupling mirror:

■ in fiber lasers as Bragg gratings
■ in diode lasers as surfaces in semiconductor crystals.
Laser machine Laser machines are machines the main purpose of which is to
weld or cut material with laser light or to process it in any other
way. In laser machines, movements of the workpieces and focus-
ing optics are mainly controlled automatically.
Laser workstation Laser workstations are facilities at which workpieces are mainly
processed manually using laser light.
1‐6 Terms 2018-04 20-10-06-A3001-

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Laser device Laser devices include all components required for generating
laser light.
Laser device components include:

■ Laser with pump source
■ Energy supply for the pump source, e.g. diode power supply,
lamp power supply
■ Control
■ Cooling unit
Depending on the type and maximum power of the laser device,

it may have other components, such as:
■ Mains distribution
■ Cabinet cooler
■ Air cleaner or recirculating air dryer system
■ Gas purging unit
Pump light cable The pump light cable is a flexible connection element between
supply unit and laser head. The pump light is guided in a light
guide from the pump diode to the laser head. Around the light
guide there are different devices to avoid uncontrolled exit of
laser light and to protect the light guide.
Laser light cable The laser light cable is a flexible connecting element between
laser device and focusing optics. The laser light is guided from
the laser to the focusing optics in a light guide. For ultrashort
pulse lasers, only so-called hollow-core fibers are suitable due to
the high peak power, where the intensive laser pulse is not con-
ducted in glass, but in a vacuum, air or another filling gas. The
light guide is surrounded by several devices that prevent an
uncontrolled escape of laser light and protect the light guide.
Focusing optics Focusing optics are optical assemblies. Their main function is to
form the laser beam so that it achieves its maximum power den-
sity at a defined point, the focal point.
In the reflective focusing optics (RFO), the conical laser beam
coming out of the laser light cable hits the focusing mirror, which
guides the laser beam through the exit port and merges it in the
focal point.
The programmable focusing optics (PFO) includes one or two
scanner mirrors which allow the laser beam to be guided over a
processing field. It is thus possible to produce, for example,
welding seams without moving the focusing optics and the work-
piece.
The distance of the focal point from a certain edge or surface of
the focusing optics is called working distance. The working dis-
tance of the focusing optics determines the distance in which the
workpieces must be positioned so that they can be processed
with the laser.
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2018-04 Terms 1‐7
Laser beam guidance The laser beam guidance deflects the output radiation of the
laser to the workpiece.
Safety circuit A safety circuit is an electric circuit for monitoring protective cov-
ers and doors of laser protective casings and cabins. When the
contacts are looped in, the safety circuit should always be closed
when all monitored covers and doors are closed.
When a contact interrupts the safety circuit because a door is
opened, for example, laser light emission is immediately stopped.
The safety circuit, as a central shutter of a laser device, stops
emission of laser lights on all light paths of the laser device.
The safety circuit of just one light path only stops light emission
on this light path. Laser light can still be emitted on the other
light paths if these safety circuits are closed.
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4. Hazards
The laser product has been built in accordance with state-of-the-

art standards and the recognized safety rules. However, there
might be dangers for persons or material property during use. If
you do not observe the accident prevention regulations, these
dangers may result in damage.
This section describes possible dangers that might be caused by
your laser product.
In the following sections, you will find information about:

■ how TRUMPF has reduced the risk by applying constructive
measures.
■ how you, as the user, can guarantee a safe operation of the
laser product by taking additional measures during its use.
4.1 Laser light
Solid state lasers generate laser light in the near infrared spec-
tral range (900 nm – 1250 nm). Using converters, the laser light
can also be produced in the visible range (400-700 nm) or in the
ultraviolet spectral region (< 400 nm).
Laser light may be hazardous to eyes and skin.
Depending on the severity of the danger, laser products are clas-
sified in laser classes.
The classification of the laser product in laser classes is defined
internationally in the EN 60825-1 and IEC 60825 standards.
The meaning of the laser classes is described briefly below. The
precise definition listing limit values can be found in the stand-
ards stated above.
Class 1 Class 1 means that the laser light of this laser product is not
dangerous in standard operation.
The laser device is classified as class 1M (acc. to EN 60825-1)
if there may be a risk when observing laser light through optical
instruments.
Class 2 A class 2 laser product only emits in the visible spectral region
(400-700 nm). A brief exposure does not involve any risk. Delib-
erate staring in the beam might be dangerous for your eyes.
Active reactions are sufficient to protect your eyes against dam-
age: Avert your eyes, move your head or close your eyes.
The laser device is classified as class 2M (acc. to EN 60825-1)
if there may be a risk when observing laser light through optical
instruments.
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2018-04 Hazards 1‐9
Class 3 Class 3 is subdivided into class 3R and class 3B acc. to EN
60825-1. A previously existing restriction of class 3 to certain
spectral ranges no longer exists.
Class 3R laser products exceed the limits of class 2. In most
cases the risk is low. The risk of injury increases with the time of
exposure. A deliberate irradiation of your eyes is dangerous.
Class 3B laser products are normally dangerous when you look
directly into the beam. The observation of diffuse reflections is
usually not dangerous. Class 3B laser products the power of
which almost reaches that of class 4 might produce light skin
injuries; they might also ignite inflammable material.
Class 4 Exposure of the eye or skin to class 4 laser products is danger-

ous. Even diffuse radiation (scattered laser light) can be danger-
ous. Class 4 laser light can ignite inflammable material and
make explosive mixtures explode.
4.2 Electric energy
While carrying out maintenance work, you can come into

DANGER contact with dangerous live parts!
Touching live electric parts can be life threatening.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Switch off the laser product prior to maintenance work.
Ø Secure the laser product 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 product is considered a fixed device. The
regionally enacted safety standards and accident prevention reg-
ulations apply accordingly
For you, as user of the laser product, this means:

■ The laser product may not be moved while switched on.
Regular check Check the electrical equipment of the laser product at regular
intervals. Defects such as loose connections or defective cables
must be eliminated immediately.
Electrical safety of the laser product must be checked regularly,
at least once every 4 years. The basis of the test is the German
1‐10 Hazards 2018-04 20-10-06-A3001-

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standard DIN VDE 0702. Beyond the scope of this standard, the
regulations for the corresponding region are to be applied.
This check must be carried out by a trained electrician. Among

other things, it consists of the following actions:
■ Visual check, for example the condition of the protective
grounding conductor and its terminal locations.
■ Test of the protective grounding conductor resistance.
Backups Use only original fuses with the specified characteristics and cur-
rent rating.
Voltage with the main switch Some components carry dangerous voltage even if the main
off switch is in the OFF position. Therefore, before touching electric
parts, first, check if they are de-energized.
Capacitors The discharge time of capacitors may be more than one minute.
Check if the parts live during operation carry voltage, after
switching off the machine. Start working on live parts only after
you have checked if they are de-energized.
4.3 Gases, aerosols, dusts
When workpieces are processed, gases, aerosols or dusts can

be produced; these are dangerous to health. The biggest risk is
caused when the substances enter your respiratory tract. But
even contact with your skin or mucous membranes in your
mouth, nose or eyes can be dangerous.
Dust:
Solid particles > 1 µm.
Aerosols:
Gases with finely distributed solid or liquid particles < 1 µm.
Some escaping substances may cause cancer. The cancer risk
depends mainly on the material of the workpieces and the emit-
ted quantity.
Carcinogenic substances include

■ beryllium compounds
■ zinc chromates
The emitted quantity depends on:

■ the type of material.
■ the speed.
■ the laser power.
■ the cutting gas pressure, if applicable.
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2018-04 Hazards 1‐11
4.4 Thermal energy
Fire, explosion
Class 3B or 4 laser light may cause fires if it ignites inflammable

material.
If there is a potentially explosive mixture of gases or aerosols
(e.g. oxyhydrogen, wood or carbon dust) in the air, a laser beam
might cause an explosion, even if it does not hit solid material
with a high power density.
Temperature of the workpiece
Due to the processing by means of the laser beam, the work-

piece may be heated up. The degree of heating depends on the
material of the workpiece and the energy given off by the laser
beam to the workpiece during processing.
Risk of burns when touching the hot workpiece

WARNING
This may result in skin injuries.
Ø Remove hot workpieces using an appropriate tool.
Ø Wear protective gloves, if necessary.
4.5 Noise
Focusing optics The use of focusing optics in conjunction with lasers and
process gas produces noise.
Sources of noise in the area of the focusing optics include:

■ Material that evaporates as a result of the exposure to laser
light
■ Cutting gas or shielding gas passed to the processing point
■ Compressed air coming out of the crossjet
During laser welding, compressed air comes out of a nozzle,
called crossjet, perpendicularly to the direction of the laser
beam. If there is a crossjet, it is often the biggest source of
noise. Measurements have given values > 90 dB(A).
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High noise level when operating a focusing optics,
WARNING especially when using a crossjet!
Noise can result in permanent ear damage and other
unfavorable consequences to health, especially upon
prolonged exposure.
Ø Surround the processing point with a protective cover that is
sufficiently silencing.
Ø Wear ear protection if the noise levels are high.
Ø Operate the focusing optics only with the silencing protective
cover closed, if possible.
The room in which a focusing optics is operated should have the

following characteristics:
■ The processing point should be as far away as possible from
places where people stay permanently.
■ Walls and devices are particularly good absorbers of noise.
■ The areas that are at risk from noise are labeled.
■ Ear protection devices are available in sufficient numbers.
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2018-04 Hazards 1‐13
5. Safety of the laser product
5.1 Laser beam emission openings
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 consist of modules according to the require-
ments of your application. The appearance may differ from the
optics shown in the figure. Several laser light cables and focus-
ing 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 some special conditions, the workpiece may reflect scat-
tered radiation with a wavelength of up to 1100 nm.
Example of conditions:
■
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 wavelength of up to 1100 nm

WARNING reflected by the workpiece!
Eye injuries!
Ø The laser safety glasses or the safety glass for observation
windows must be selected with regard to the wavelength of
the scattered radiation.
Wavelengths Laser Wavelength Spectral range

Yb: YAG 1030 nm near infrared
Pilot laser 630 - 680 nm visible, red
Tab. 1-1
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Laser classes Device, component Laser class
Laser device with closed hood 1
Laser device with open hood 4
Laser light cables 1
Focusing optics under a closed protective cover 1
Focusing optics without protective 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 1
Tab. 1-2
5.2 EMERGENCY STOP push-button

(option)
The EMERGENCY STOP push-button is optionally available. The

EMERGENCY STOP push-button is fitted on the front of the
laser device.
EMERGENCY STOP push-button (arrow) Fig. 1-2
Pressing the "EMERGENCY STOP" push-buttons, all compo-

nents of the laser device which can be dangerous are immedi-
ately stopped. After the EMERGENCY STOP push-button has
been pushed no more laser light comes out.
Further push-buttons Additional EMERGENCY STOP push-buttons can be connected

to the laser device. The EMERGENCY STOP circuit of the laser
device can be integrated in the EMERGENCY STOP circuit of a
system which include the laser device. More information is given
in the interface description of the EMERGENCY STOP.
Function test Check the function of the EMERGENCY STOP push-buttons if

you have modified the EMERGENCY STOP circuit of the laser
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2018-04 Safety of the laser product 1‐15
device. TRUMPF cannot be held liable for any damage resulting
from the incorrect wiring of the EMERGENCY STOP circuit.
Performing risk assessment Perform a risk assessment for the system.
According to the results:

■ Install a suitable safety device.
■ Wire the EMERGENCY STOP circuit.
■ If there are changed to the system, adjust the wiring of the
EMERGENCY STOP circuit according to the requirements.
A risk assessment must also be carried out on systems for devi-
ces without an EMERGENCY STOP and installed in accordance
with the safety device.
5.3 Safety circuits
The control unit of the laser device contains interfaces for safety
circuits (SIK).
What is a safety circuit? A safety circuit is an electric circuit used to monitor the protec-
tive 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 to operate entire systems as class 1 laser

products.
ASV board Each safety circuit is connected to the ASV board located in the
control unit of the laser device. The ASV board controls an opti-
cal shutter which prevents laser light leaving the laser when the
safety circuit is open.
ASV: Arbeits- und Sicherheits-Verschluss (operating and safety
shutter).
Mode of operation The following picture shows the general mode of operation of a
safety circuit.

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WS-00101
1 Laser control system 3 Door contact closed 4 Door contact open
2 Shutter
Safety circuit, principle Fig. 1-3
Operating 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 image below the safety circuit is open because the door
to the enclosed protective housing has been opened. The shutter
is switched to CLOSED position by means of the ASV board in
the control unit. No laser light is emitted at the processing point
anymore.
Laser light upon “Laser On” When the safety circuit is closed and the shutter is open, laser
light > 5 mW can be emitted from the laser beam emission
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openings after having switched on the laser, even if the com-
mand to trigger the laser has not yet been started.
5.4 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 releasing laser light, even if no laser
light is emitted at the processing point yet (“laser on” status).
External laser warning lamp Additional laser warning lamp can be connected to the laser
device and attached, for example near the workstation.
Further information is given in the interface descriptions of
EMERGENCY STOP and ASV.
5.5 Key-operated switch
Fig. 1-5

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Key-operated switch
Fig. 1-6
The key-operated switch enables to prevent unauthorized

starting of the laser. For this purpose, the key must be brought
to position Laser locked (chart A) and be removed.
The key must be inserted during operation. The key-operated
switch must be turned to the position Release laser (chart B).
5.6 Labels and warning signs
The labels and warning labels attached to the laser product and
in the range of the focusing optics are described in this section.
The point of fastening is indicated for each label.
Required signs
Notes regarding power and wavelength of the pilot laser Fig. 1-7
Notes regarding power and wavelength of the pilot laser Fig. 1-8
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3
Warning against dangerous electrical voltage Fig. 1-9
Warning of dangerous laser radiation Fig. 1-10
Warning of dangerous laser radiation Fig. 1-11
6 TruDisk 3000 / 3001 / 3002 / 3006 / 4000 / 4001 / 4002 / 4006
Information on power and wavelength of the laser Fig. 1-12
6 TruDisk 5001 / 5002 / 5006 / 6001 / 6002 / 6006
Information on power and wavelength of the laser Fig. 1-13

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7
Fig. 1-14
Fig. 1-15
Reference to laser class Fig. 1-16
10
Type plate of the laser device (example) Fig. 1-17
11
Note: "Observe the operating instructions when checking the Fig. 1-18
electrical system"
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12
Note: "In case of frost, leakage of cooling water," Instruc- Fig. 1-19
tions: see Operator's manual
13
Fig. 1-20
Labels on the laser device
The following pictures show the location of the labels on the

laser devices. The numbers show the assignment of the section
"Required labels".

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Fig. 1-21
Fig. 1-22
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Label in the area of the focusing optics
The laser device is delivered with 3 copies of label "Avoid expo-

sure to laser radiation".
It is an adhesive label with removable protective film.
The label is not attached because the arrangement of the work-
station on which the focusing optics is to be fitted is normally not
known at the time of delivery.
Mandatory marking As the operator of the laser device you are obliged to attach the
label next to the focusing optics, so that it is visible for the per-
sons staying within this area.

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6. Measures of the user
6.1 Designated use of the laser product
The laser device is intended exclusively for processing solid met-

als or metal alloys.
Intended use also includes the following:

■ observing the instructions set out in this operating manual.
■ wiring and connecting electric lines to the laser product in
compliance with the regulations regarding electromagnetic
compatibility.
■ Do not move the laser device in a switched-on state.
■ carrying out necessary inspections and maintenance work.
Exceptions The laser device is not intended for processing metals or metal
alloys in connection with flammable or explosive materials
(example: containers filled with combustible gases or fuel, ammu-
nition).
The laser product must not be operated in an environment sub-
ject to explosion hazards.
6.2 Technical measures
Condition of the laser The laser product may only be used if it is in perfect technical
product condition. Any faults, especially those affecting safety of the unit,
must be eliminated immediately!
Modifications Do not modify the laser product without previous consent of

TRUMPF as this may impair the safety of the laser product.
Spare parts Spare parts must comply with the requirements specified by
TRUMPF. This is guaranteed with original spare parts.
Software Do not modify the software programs in programmable compo-

nents.
Cable Always lay the laser light cable and the electric cables in such a
way that they are protected and the minimum bending radius is
observed.
Keep the cables away from:

■ traffic routes.
■ moving or heavily vibrating machine parts.
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2018-04 Measures of the user 1‐25
Separate ground cable If the ground cable cannot be connected via the mains cable,
the ground cable must be connected separately to the grounding
of the building. The ground cable must be installed protected so
that it cannot be damaged or disconnected. The ground cable
may only be connected by trained electricians.
protective covers Always cover the focusing optics, laser beam path and process-
ing points with protective covers, as far as possible. Protective
covers must be designed in such a way that laser light cannot
escape.
Protective covers can be:

■ Housings in which focusing optics and processing point are
located.
■ Walk-in protective cabins.
All parts of protective covers that can be opened by the operat-
ing personnel during operation must be monitored. Monitoring
must be designed such that laser light emission is stopped
immediately when a protective cover is opened.
Protective covers that are opened only for repair have to be
monitored in the same way. If they are not monitored, tools must
be required for opening them.
TRUMPF laser devices have safety circuits that guarantee the
described safety function when they are appropriately wired.
More information is given in the interface description of the laser
devices.
Walk-in protective cabins should additionally be equipped with
motion detectors or similar equipment. This allows to determine
whether there are persons in the protective cabin even if the
cabin door is closed.
Cordoning off the hazardous Cordon off the areas in which laser light can escape to prevent
area access of unauthorized persons, for example by using code
locks or suitable signaling devices.
6.3 Organizational measures
Laser safety officer If your company operates a class 3B, 3R or class 4 laser prod-
uct, appoint a laser safety officer. Make sure that this person is
qualified and can assess the hazards caused by the laser and
take appropriate measures. Put this laser safety officer in charge
of supervising the protective measures against hazards caused
by the laser.
Selecting and qualifying As the laser device user, only employ trained or instructed staff.
personnel Clearly specify the individual responsibilities of the persons for
operation, setup and servicing.
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Registering the laser As the user, you are obliged to report the operation of class 3B
product and class 4 laser products to the authorities responsible for laser
safety.
If you have any questions, contact the local sales office of
TRUMPF.
Skilled electrician According to the rules of electrical engineering, any work on the
electrical system of a laser product may only be carried out:
■ by an electrician.
■ by instructed persons under the supervision and guidance of
an electrician.
6.4 Observing standards and regulations
Some important standards and regulations which you have to

observe when operating a laser product are listed in the follow-
ing table. This list is for information purposes only and probably
incomplete.
As the operator, you are responsible for ensuring that the stand-
ards and safety regulations in force in your region are observed
as far as they are mandatory.
International standards IEC 60825 Radiation safety of laser products

EN 60825 Safety of laser products
EN 207 Filter and safety glasses against laser radiation
(laser safety glasses)
EN 60204 Electrical equipment of machines
Tab. 1-3
6.5 Behavior in certain operating stages
Standard operation Operate the laser product only when all protective and safety rel-
evant devices, - e.g. Emergency Stop equipment, protective cov-
ers, safety contacts, exhausters - are in place and fully opera-
tive.
Open the safety circuit of the light path in question when an
error occurs. Have any defects eliminated immediately.
Maintenance Service work may be carried out by trained personnel only.

For maintenance and repair, open the safety circuits of all
affected light paths and make sure that they remain open for the
entire duration of the work.
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Before working on the electrical system of the laser product, turn
the main switch OFF. Lock the main switch in this position using
a shackle padlock.
Carry out the adjustment, maintenance and service work stated
in these operating instructions in due time. Observe information
regarding the replacement of parts.
Check the correct functioning of the safety devices of the laser
product regularly.
6.6 Behavior in case of emergency
Cases of emergency include:

■ Laser light escapes unexpectedly.
■ A part of the machine in which the laser product is operated
makes uncontrolled movements.
■ There is a fire or explosion.
■ Substances which might affect the health are leaking.
If you assume that these or similar events might injure persons
or damage material, take appropriate measures.
If the case of emergency is caused by the laser product, push
the EMERGENCY STOP push-button to stop laser light emis-
sion and movements of the machine.
The EMERGENCY STOP push-button is an option for this ser-
ies.
Further measures depend on the situation.
TRUMPF recommends you, as the operator of a laser product,
to identify the possible risks in a risk analysis and to define suit-
able measures for minimizing the risks or as first-aid measures
when people are injured.
Prepare directives describing the behaviors in case of emer-
gency. Attach the directive in the dangerous area so that every-
one can read it.
6.7 Selecting and qualifying personnel
Only use trained and instructed staff.
Define the responsibilities on the laser product for:

■ Setup
■ Operation
■ Maintenance

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Any work on the electrical equipment of a laser product must be
carried out by a trained electrician only.
Instructed personnel may work on the electrical equipment if

■ the rules for electrical safety are observed.
■ the work is carried out under the supervision and guidance
of a trained electrician.
6.8 Instructing the personnel
Operator’s obligations As the operating company, make sure that all persons operating
the laser product have the knowledge and qualifications to do
so. In particular, the personnel needs the required awareness of
possible dangers that might be caused by the laser product.
Reading the operating Before starting the work, the personnel entrusted with work on
instructions the laser product must have read the operator’s manual and the
chapter "Safety" in particular. This applies especially to persons
working only occasionally on the laser product, e.g. during main-
tenance.
Training with TRUMPF If required, TRUMPF offers trainings for operators and personnel
responsible for maintenance. Please contact the TRUMPF serv-
ice department.
Directives Inform any person in the dangerous areas by means of direc-

tives. Attach the directives clearly visible and protected in the
dangerous areas.
Directives are short informative texts, mostly not longer than a

page, which present all essential information to
■ avoid dangers as far as possible
■ act correctly if accidents occur in spite of safety measures.
Signs Please observe the labels attached to the laser product. Ensure
that the labels are in a legible state. Any labels that are dam-
aged or not longer legible must be replaced.
For further information on the labels: see section "Labels"
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6.9 Wearing personal protective
equipment
If your risk analysis for the laser product shows that technical
measures are not enough, persons can be protected in addition
by wearing a personal protective equipment.
Examples:
■ Laser safety glasses to protect the eyes against escaping
laser light.
■ Gloves to protect the hands against hot workpieces.
■ Respiratory equipment to protect the respiratory tract against
hazardous substances.
Please make sure that the provided personal protective equip-
ment is effective. In case of laser safety glasses, for example,
the filtering glasses have to be suitable for the wavelengths of
the laser light emitted by the laser. The optical density of the fil-
tering glasses
must be adapted to the beam intensity.
Clearly regulate wearing of personal protective equipment, e.g. in
a directive.
Make sure that this regulation is observed.
Punish any violation of this regulation.
6.10 Disposal
Scrapping of the laser device may produce substances that are

dangerous to persons or the environment. The laser modules
contain gallium arsenide (GaAs) which may be released by
scrapping if the housing of the laser modules are crushed.
GaAs is:
■ toxic if inhaled or swallowed.
■ carcinogenic for humans.
■ severely harmful to water, particularly for aquatic organisms
(fish, plankton etc.).
As long as the housing of the laser modules is not open or dam-
aged, GaAs does not pose any danger.
Always dispose of pump modules in accordance with the respon-
sible local waste disposal authority and observe the local regula-
tions.

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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
2.2 Free space for service work 2‐8
2.3 Panel computer (option) 2‐8
2.4 Laser light cable 2‐9
3 Weight, floor at the installation site 2‐12
4 Connections: 2‐13
4.1 External connections 2‐13
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2018-04 Installation conditions, Transport 2‐1
4.2 Electrical interfaces 2‐14
5 Connected loads 2‐17

5.1 Electrical connection 2‐18
5.2 Electromagnetic compatibility 2‐20
5.3 Insulation resistance 2‐20
6 Cooling unit 2‐22

sioning
sioning
sioning
sioning
6.5 "Extended ambient conditions" option 2‐34
Determining dimensioning data 2‐35
6.6 Cooling water connections 2‐37
6.7 Data for chillers 2‐37
6.8 Laser cooling circuit 2‐39
7 Ambient conditions 2‐40
8 Emissions 2‐42
9 Operator’s stand 2‐43

9.1 Location for switching the laser device on and 2‐43
off
9.2 Location for laser device operation 2‐43
9.3 Location for adjustment of the focusing optics 2‐44
9.4 Location for maintenance work 2‐45
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10 Measures to be taken on delivery of the 2‐46
laser device
10.1 Delivery of the laser device 2‐46
10.2 Start-up 2‐46
11 Transport 2‐47
11.1 Transport by means of pallet jack 2‐47
11.2 Transporting by fork lift 2‐49
11.3 Moving the laser device on wheels 2‐52
11.4 Packing the laser device 2‐54
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2018-04 Installation conditions, Transport 2‐3
1. Scope of delivery
Laser devices by TRUMPF are configured, equipped with acces-

sories and delivered according to the user requirements. There-
fore, each delivery is assembled individually.
The following pages give information on:

■ the basic scope of delivery.
■ important optional components.
■ the documents included in the delivery.
The total scope of delivery is listed on the delivery note. This
note contains additional information which may be important to
identify components, for example material numbers.
The components are described in the chapter "Description".
1.1 Components of the laser device
1 Panel computer (option) 2 Laser device

Fig. 2-1
Panel computer A panel computer can optionally be included in the scope of

delivery.
It is possible to install the operating software TruControl 1000
Module Remote on any PC. The PC must meet the requirements
specified by TRUMPF. Further information can be obtained from
TRUMPF on request.
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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
machining task to be performed by the laser device.
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 the delivery Details on the delivered articles including material number and
note! number of pieces are specified on the delivery note.
1.3 Documents
The following documents are included in the delivery:

■ Operator's manual.
■ Software manual.
■ Interface descriptions.
■ Dimensional drawings, for example for the focusing optics.
■ Declaration of Incorporation or Declaration of Conformity.
■ Acceptance protocol.
■ Circuit diagrams for TRUMPF Service.
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2018-04 Scope of delivery 2‐5
■ Labels and warning signs to be attached to the workstation.
■ Optional: Documentation of components by other manufactur-
ers
For example:
− Operator's manual for a CCD camera which is operated
on focusing optics.
− Documentation of the chiller.
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2. Dimensions
All dimensions in millimeters [mm].
2.1 Laser device
Front view and left side view Fig. 2-3
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2018-04 Dimensions 2‐7
2.2 Free space for service work
Fig. 2-4
The laser device has to be freely accessible from all sides for
service work. In addition, tools and measuring devices require
space.
The indicated space represents the minimum clearance around
the laser device required for service work.
2.3 Panel computer (option)
Fig. 2-5
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2.4 Laser light cable
Fig. 2-6
Length The length of the laser light cable depends on the distance
between laser device and focusing optics.
The documentation for the laser device contains information on
the dimensions of the laser light cable.
bend radius The bend radius of the laser light cable must not be smaller
than 200 mm.
Installation To install the laser light cable corresponding paths and spaces
must be provided.
Laser light cable must be layed in a way to avoid tension, kink-
ing and torsion.
2.5 Focusing optics
Focusing optics consist of modules as required by the process-

ing task.
Dimensions The dimensions are determined by the components used to pro-

duce your focusing optics.
Free space Ensure free space around the focusing optics, especially for:
■ unhindered emission of laser light.
■ setting work.
■ maintenance and service work.
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Documents Information on dimensions, fastening and free space is given 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.
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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 the focusing optics (example) Fig. 2-7
In addition to the dimensions, the drawing contains letters. The

arrow points to the letter e.
The dimensional drawing for the holes "Cube 90" is given in the
installation directive under "e".
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Dimensional drawing for "Cube 90°" in the installation Fig. 2-8
instructions
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3. Weight, floor at the installation site
Weight Weight laser device 4.7 kN (470 kg)

Maximum load per caster 1.6 kN (160 kg)
Tab. 2-1
Height difference of the floor Install the laser device as horizontal as possible! Level differen-
ces of the floor at the installation site cannot be compensated
using the castors.
Vibrating charge Maximum acceleration of vibration in vertical and horizontal

directions: 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.
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4. Connections:
4.1 External connections
1 Cable entry system for e.g. 3 Condensate drain, connection 5 Cooling water supply
external interfaces for hose ∅ 8 mm, standard 6 Cable bushing for mains cable
2 Connection for equipotential O.D. tubing
bonding 4 Cooling water return
External connections Fig. 2-9
Cooling water connections The cooling water hoses are mounted on a hose nozzle which is
fitted to the laser device by means of knurled nuts.
Further Information on the connection and the hose and thread
dimensions: (see "Cooling water connections", pg. 2‐37)
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2018-04 Connections: 2‐13
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.
1 Fieldbus interface (option) 5 Scanner port (option) 9 EMERGENCY STOP interface

2 Parallel and real-time interfaces 6 Analog input (option) (option)
3 Ethernet for LAN connection 7 Focusing optics interface 10 Safety circuit interface
(panel computer) (option) 11 Interface for external laser warn-
4 Analog output (option) 8 Switch-on interface ing lamp
12 Peripheral bus interface
Control and part of the mains distribution Fig. 2-10
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. Further information on this topic is given in chap-
ter "Operating" and the interface description for the laser device.
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You can also control the laser device by means of one of the fol-
lowing fieldbuses:
■ Profibus-DP
■ DeviceNet
■ Powerlink
■ ProfiNet
In this case, the board of the selected fieldbus system is instal-
led in one of the free spaces for the fieldbus modules. Informa-
tion on pin assignment and data format is given in the interface
description of the selected fieldbus system.
The following fieldbus interfaces can still be implemented via the

TRUMPF Peripheral Bus (TPB) fieldbus system:
■ Interbus
■ Ethernet/IP
■ EtherCAT
■ Analog interface
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 given in the interface description of the
ASV.
Switch-on interface The contacts required to activate the "Control ON" and "Control
OFF" functions from an external device (for example a PLC) are
provided on the interface X2. Besides, the interface has contacts
for connecting an external laser warning lamp and an external
monitoring lamp.
EMERGENCY STOP interface The EMERGENCY STOP interface allows you to:
■ connect further EMERGENCY STOP push-buttons to the
laser device.
or
■ integrate the laser device in a higher-ranking EMERGENCY
STOP circuit.
The higher-ranking EMERGENCY STOP circuit can be part of a
system which comprises the laser device.
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2018-04 Connections: 2‐15
Note
When installing the cable to an external EMERGENCY STOP
device, make sure that it cannot get pinched or rolled over.
Peripheral bus interface The TRUMPF peripheral bus is a field bus system based on
real-time Ethernet. The TRUMPF peripheral bus components are
designed for installation on DIN mounting rails (35 mm) accord-
ing to EN 50022.
More information is given 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 in the software the
signal to be scanned at a connector for measuring purposes.
Measuring instruments (such as an oscillograph) can be con-
nected directly to the output signals.
More information is given in the interface description "Analog
output of the DLC board".
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5. Connected loads
Mains 380 V (-10 %) ... 460 V (+10 %)

50 Hz (-3 Hz) ... 60 Hz (+3 Hz)
Further data according to EN 60204-1, TN
mains according to IEC 60364-1.
cos φ (DPF) at nominal 0.96
power
λ with rated power (total 0.96
power factor)
Insulation resistance 260 kΩ
Maximal admissible ≤ 180 mΩ
source impedance Zv at
If the source impedance ZV at the system
the system connection
connection point is exceeded, the protec-
point.
tive measures against electric shock have
to be evaluated again by a trained electri-
cian.
Back-up fuse TruDisk 3000, TruDisk 3001,
Mains dimensioning TruDisk 3002, TruDisk 3006,
TruDisk 4002, TruDisk 4006: 32 A
TruDisk 6002, TruDisk 6006: 50 A
Operating class gl/gG line protector
Clamping range cable TruDisk 3000, TruDisk 3001,
entry system mains cable TruDisk 3002, TruDisk 3006,
TruDisk 4002, TruDisk 4006:
11 mm - 20 mm
20 mm - 32 mm
Tab. 2-2
The service case details apply to the network configuration.
Operating status Power [kW] Power [kVA] Current with 400 V Use
[A]
Electrical power at laser 11.2 12 17.5 Consumption data
rated power on the work-
piece
Maximum power con- 16.4 17.2 29 Case of service
sumption
TruDisk 3000, TruDisk 3001, TruDisk 3002, TruDisk 3006 Tab. 2-3
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[A]
Electrical power at laser 14.2 15.2 22 Consumption data
piece
Maximum power con- 19.2 20 34 Case of service
sumption
TruDisk 4000, TruDisk 4001, TruDisk 4002, TruDisk 4006 Tab. 2-4
[A]
Electrical power at laser 17.2 18.4 26 Consumption data
piece
Maximum power con- 22 23 39 Case of service
sumption
TruDisk 5001, TruDisk 5002, TruDisk 5006 Tab. 2-5
[A]
Electrical power at laser 20.5 22 31 Consumption data
piece
Maximum power con- 26 27.5 40 Case of service
sumption
TruDisk 6001, TruDisk 6002, TruDisk 6006 Tab. 2-6
Residual current protective If necessary, use a universal ground-fault circuit interrupter (RCD
device type B).
Electrical inspection Check the electrical safety of the laser device regularly ‑ at least
every 4 years.
More information has been given in chapter "Safety" of the oper-
ator's manual, section "Electrical energy".
For operation of the laser device at mains voltage different from

voltages specified above, you have to use a series transformer.
Contact TRUMPF, if you need further information on this.
5.1 Electrical connection
Mains cable with CEE plug Length Usable length 5 m

option Cable cross section 4 x 6 mm2
Plug CEE 32 A-6h as per DIN EN 60309
Mains cable TruDisk 3000 - 4006 Tab. 2-7
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Length Usable length 5 m
Cable cross section 4 x 16 mm2
Plug CEE 63 A-6h as per DIN EN 60309
Mains cable TruDisk 5001 - 6006 Tab. 2-8
The mains cable is firmly connected to the laser device and

designed for the following parameters.
Ambient temperature 50 °C
Line voltage Line voltage
(380V -10%)
Installation On surfaces
Accumulation None
Tab. 2-9
If this parameter is exceeded, a suitable mains cable must be

used.
Mains connection option With the mains connection option, an industrial plug-in connector
is attached to the housing.
Mains connection TruDisk 3000 – 4006:
Plug housing Harting item no. 09 31 006 2601

Included in the Socket insert Harting item no. 09 31 006 2701
scope of delivery Grommet housing Harting item no. 19 30 016
1522 and cable screw union for the counterpart
Connection cross- 1.5 mm² to 6 mm²
section
Tab. 2-10
Pin 1 L1
Pin 2 L2
Pin 3 L3
Pin 4 to Pin 6 NC
PE PE
Connector assignment mains connection TruDisk 3000 – Tab. 2-11
4006
Mains connection TruDisk 5001 – 6006:
Plug housing Harting item no. 09 38 008 2601

Included in the Socket insert Harting item no. 09 38 008 2701
scope of delivery Grommet housing Harting item no. 19 30 010
0547 and cable screw union for the counterpart
Connection cross- 6 mm² to 16 mm²
section
Tab. 2-12
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Pin 1 L1
Pin 2 L2
Pin 3 L3
Pin 4 NC
Pin PE PE
Pin 11-14 NC
Connector assignment mains connection TruDisk 5001 – Tab. 2-13
6006
Customer-supplied mains The following connected loads refer to the line filter terminal:
cable, option
TruDisk 3000 - 3006 TruDisk 4001 - 6006
Multiwire 10 mm2 25 mm2
Solid 16 mm2 35 mm2
AWG/kcmil 6 4
Torque 1.2 Nm 2 - 2.2 Nm
PU connect- M5 M5
ing bolts
Maximum clamping area Tab. 2-14
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. Data for
line connection are given in the interface description “Interfaces
of the laser devices”.
The laser device is only suitable 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 allowed insulation resistance for this laser type is listed in
(see "Tab. 2-2", pg. 2‐17). If the value does not fall below the
value defined, the laser device can be registered as "OK".
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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 during a regular check of the electrical devices you discover
that a TRUMPF laser device has an insulation resistance
< 1 MΩ, proceed as follows:
Check regularly 1. Check the minimum allowed insulation resistance of the laser
device (see "Tab. 2-2", pg. 2‐17).
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 for the small value and repeat the measure-
ment.
One possible reason may be a performed technical modifica-

tion on the laser device after delivery, this modification may
influence the insulation resistance.
or
Ø If you cannot find the cause or if it is not possible to
eliminate it, contact the TRUMPF service and agree the
further proceeding with the service.
The contact details (telephone number, etc.) of the serv-
ice department are given on the first page of the operat-
ing instructions of the laser device.
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6. Cooling unit
6.1 External cooling circuit TruDisk

3000, TruDisk 3001, TruDisk 3002,
TruDisk 3006
Supply temperature +5 °C .. +28.5 °C

"Extended ambient conditions" option:
+5 °C .. +25 °C
Pressure ≤ 6 bar
Pressure difference Δp 0.2 bar ≤ Δp ≤ 6 bar
between supply and
(see "Fig. 2-12", pg. 2‐23)
return at the laser
device "Extended ambient conditions" option:
1 bar ≤ Δp ≤ 6 bar
(see "Fig. 2-23", pg. 2‐35)
Minimum water require- (see "Fig. 2-11", pg. 2‐23)
ment
Water quality Cooling water tower according to VDI 3803,
appendix B, table B3.
If the water is heavily contaminated, a prefil-
ter ≤ 135 µm (filter level in the device
250 µm) must be installed.
Water additives Operation with water additives (e.g. anti-
freeze, algae protection, etc.) is possible if it
has been ensured that the materials used in
the cooling system are not attacked.
Water additives reduce the cooling capacity.
Operation with water additives is possible

only:
■ at lower supply temperatures or
■ at reduced laser power or
■ at increased flow rates
Connections of supply (see "Cooling water connections", pg. 2‐37)
and return
Material V2A, V4A, brass/red brass, PVC-U, EPDM,
red brass, NBR, copper
Tab. 2-15
Note
Note that the differential pressure refers directly to the connec-
tions of the laser device. Connected hoses cause an additional
pressure drop. This pressure drop depends on the length and
diameter of the hoses.
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Cooling water consumption for pipe
dimensioning
Minimum water consumption characteristic Fig. 2-11
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.
Pressure drop curve Fig. 2-12
The flow rate is shown here using the minimum pressure differ-
ence of the laser cooler (with open internal valves). Note that
this is the pressure difference at the connections of the laser
device.
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2018-04 Cooling unit 2‐23
Determining dimensioning
data
Example Fig. 2-13
Note
When dimensioning the piping for the external cooling water,
make sure that the required differential pressure is applied
directly to 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 at maximum power
consumption at a supply temperature of 21℃ = 1.45 m³/h.
3. Read the pressure drop which is generated at this flow rate
between the supply and the return of the cooling unit at the
pressure drop characteristic (Fig. "Example" right) on the
right side.
- In the example: 0.2 bar.
To ensure the function of the internal solenoid valves,
the minimum pressure difference of 0.2 bar must be
reached!
4. When selecting hose cross-sections and hose lengths,
TRUMPF recommends a safety factor of 0.5 bar in order to
compensate for slight contamination of the filter and for
measuring inaccuracies on site.
The determined values for water consumption and pressure drop
have to be dimensioned in a way that the reliable operation of
the laser device is guaranteed. Laser device operation with lower
values reduces the regulation reserve of the cooling unit. This
may cause a frequent display of monitoring or fault messages
because of excess temperature. Such messages interrupt the
operation of the laser device.
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4000, TruDisk 4001, TruDisk 4002,
TruDisk 4006

+5 °C .. +25 °C
Pressure ≤ 6 bar
between supply and
(see "Fig. 2-12", pg. 2‐23)
return at the laser
(see "Fig. 2-23", pg. 2‐35)
ment

only:
and return
Tab. 2-16
Note
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dimensioning

device.
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data
Example Fig. 2-16
Note
left).
consumption at a supply temperature of 21℃ = 1.7 m³/h.
right side.
reached!
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5001, TruDisk 5002, TruDisk 5006

+5 °C .. +25 °C
Pressure ≤ 6 bar
between supply and
(see "Fig. 2-12", pg. 2‐23)
return at the laser
(see "Fig. 2-23", pg. 2‐35)
ment

only:
and return
Tab. 2-17
Note
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dimensioning

device.
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data
Example Fig. 2-19
Note
left).
consumption at a supply temperature of 21℃ = 2 m³/h.
right side.
reached!
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6001, TruDisk 6002, TruDisk 6006
Supply temperature +5 °C .. +28 °C

+5 °C .. +25 °C
Pressure ≤ 6 bar
Pressure difference Δp 0,2 bar ≤ Δp ≤ 6 bar
between supply and
(see "Fig. 2-12", pg. 2‐23)
return at the laser
(see "Fig. 2-23", pg. 2‐35)
ment
ter ≤ 135 μm (filter level in the device 250
μm) must be installed.

only:
and return
Tab. 2-18
Note
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dimensioning
Curve of minimum water requirement Fig. 2-20

device.
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data
Example Fig. 2-22
Note
left).
consumption at a supply temperature of 21 °C = 2,11 m³/h.
right side.
- In the example: 0,2 bar.
reached!
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6.5 "Extended ambient conditions"
option
Supply temperature +5 °C .. +25 °C

Pressure ≤ 6 bar
Pressure difference Δp 1 bar ≤ Δp ≤ 6 bar
between supply and
(see "Fig. 2-23", pg. 2‐35)
return at the laser
device
Minimum water require- The minimum water requirement is made up
ment of the water requirement of the standard
laser device and the additional water
demand of the "Extended ambient condi-
tions" option.

only:
and return
Tab. 2-19
Note
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device.
Use of an additional heat exchanger in the optical compartment
results in additional water consumption. The additional water
consumption must be added to the water consumption deter-
mined above. In the example - 300 l at pressure difference of 1
bar.
Additional water consumption pressure drop curve Fig. 2-24
Determining dimensioning data
1. Determine the minimum water requirement for standard laser

devices.
- Example TruDisk 5001: water consumption at maximum
power consumption and supply temperature of 21°C is
2 m³/h.
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2. Add an additional water requirement of 300 l.
- Example TruDisk 5001: water consumption at maximum
power consumption and supply temperature of 21°C is
2.3 m³/h.
pressure drop characteristic(see "Fig. 2-23", pg. 2‐35).
- In the example: 1 bar.
the minimum pressure difference of 1 bar must be
reached!
5. TRUMPF recommends to reduce the pressure difference to
the required minimum in order to avoid unnecessary load on
the chiller.
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6.6 Cooling water connections
1 Hose 1 " 3 Hose connection 5 External cooling circuit, return

2 Hose clip 4 Union nut 1¼ " 6 External cooling circuit, supply
Fig. 2-25
Note
If the laser is not used, shut off the domestic water connections
in the supply and return of the external cooling circuit.
6.7 Data for chillers
If you operate the laser device together with a chiller, the chiller
has to meet the requirements stated in the table below.
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Cooling capacity TruDisk 3000, TruDisk 3001, TruDisk 3002,
TruDisk 3006: ≥ 14.5 kW
TruDisk 4000, TruDisk 4001, TruDisk 4002,
TruDisk 4006: ≥ 17 kW
TruDisk 5001, TruDisk 5002, TruDisk 5006:
≥ 19.6 kW
≥ 20 kW
(Cooling power on request of the maximum
system reserve)
Minimum water circula- TruDisk 3000, TruDisk 3001, TruDisk 3002,
tion quantity TruDisk 3006:
(see "Fig. 2-11", pg. 2‐23)
TruDisk 4000, TruDisk 4001, TruDisk 4002,
TruDisk 4006:
(see "Fig. 2-14", pg. 2‐26)
(see "Fig. 2-17", pg. 2‐29)
(see "Fig. 2-20", pg. 2‐32)
(see ""Extended ambient conditions" option",
pg. 2‐34)
Pressure difference (see "Fig. 2-12", pg. 2‐23)
Supply - return
(see "Fig. 2-23", pg. 2‐35)
Overflow valve required
Tab. 2-20
X inside the laser device Z required feed pressure of the

Y connecting lines pump in the chiller
Fig. 2-26
The chiller pump must be designed for the total pressure drop
(pressure drop in the laser device + pressure drop of the con-
necting lines).
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Example Pressure drop in the Pressure drop of Required feed pressure
laser device at 2000 l/h the connecting of the pump in the
(see "Fig. 2-12", lines chiller
pg. 2‐23)
0.2 bar + 1 bar = 1.2 bar
Tab. 2-21
6.8 Laser cooling circuit
Coolant
Treatment method Demineralized, deionized (DI water).
For the extraction of DI water, water of drinking
water quality must be used.
Quantity ca. 55 l (4x)
Conductivity 6 - 10 μS/cm
Total number of < 100 KBE/ml
germs
Cooling water Water Care-Copper
additives
Information on the laser cooling circuit Tab. 2-22
The cooing water additive Water Care-Copper must be added to

the DI water. Water Care-Copper increased the conductivity of
the DI water.
Treated DI water during operation

Maintenance 1 - 2 h of purification with biocide once a year
Indications regarding the laser cooling circuit during opera- Tab. 2-23
tion
Notes
■ Water Care-Copper must be used.
■ When refilling DI water, check the use of Water Care-Copper.
■ No operation of the cooling unit with a conductivity of the DI
water ≤ 5 μS/cm. The operation with a conductivity
≤ 5 μS/cm damages the components in the laser cooling cir-
cuit.
Cooling of external DI water from the cooling circuit of the laser can result in
components by other corrosion in components containing materials not resistant
manufacturers 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 third-party products.
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7. Ambient conditions
Tempera- Operation +10 °C .. +50 °C

ture
Storage
Relative Operation max. 100 % at 28 °C
humidity
Storage "Extended ambient conditions" option:
max. 100 % at 32 °C
Protection Laser IP 54 with closed doors and covering
type device
Tab. 2-24
Height above sea level Installation site >2000 m above sea level, only with upstream
overvoltage protection of 2.5 kV.
IP 54 The type of protection IP 54 is only available if all hoods, doors

and covers are closed. If the environment has a high concentra-
tion of dust and aerosols, TRUMPF recommends to protect the
laser device by a housing which protects the laser device
against the influences of the environment even if 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 diagram max. 100 % at 28 °C Fig. 2-27
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"Extended ambient
conditions" option
Dew point diagram max. 100 % at 32 °C Fig. 2-28
To determine the ambient conditions, measure the ambient tem-

perature and humidity near the laser device. During operation of
the laser device, these measured values must be within the grey
surface in the dew point diagram.
If the required ambient conditions cannot be maintained, appro-
priate conditions must be created artificially for the laser device
(cabin, air-conditioning).
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8. Emissions
Sound level Laser device LpA ≤ 70 dB(A) according to

DIN ISO 3744
Processing point Depending on the application
Tab. 2-25
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9. Operator’s stand
The following sections describe the workplaces of persons in dif-

ferent situations during operation of the laser device. These sit-
uations are:
■ Switching the laser device on and off.
■ Operating the laser device.
■ Maintenance of the laser device.
9.1 Location for switching the laser

device on and off
Fig. 2-29
Note
Install the laser device in a place where the main switch can be
reached easily.
9.2 Location for laser device operation
Fig. 2-30
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2018-04 Operator’s stand 2‐43
All operating steps of the laser device can be executed at the
panel computer or Windows PC after the laser device has been
switched on.
9.3 Location for adjustment of the

focusing optics
Fig. 2-31
Adjustment of the focusing optics is performed at the worksta-

tions.
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9.4 Location for maintenance work
1 Laser cooler 3 Focusing optics 5 Diode power supply

2 Laser light cable 4 Connections: 6 Electric fuses
Fig. 2-32
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2018-04 Operator’s stand 2‐45
10. Measures to be taken on delivery of
the laser device
10.1 Delivery of the laser device
Inspect all parts of the laser device and the accessories for
signs of transport damage immediately after delivery.
Report transport damage immediately to the following authorities:

■ the shipping agent.
■ the insurance agency which has insured the transport.
■ the dispatch department of TRUMPF Laser.
10.2 Start-up
The laser device must only be commissioned by TRUMPF per-

sonnel or persons especially trained for this type of work.
DI water For the commissioning of the laser device, keep at hand enough
deionized water (see "Laser cooling circuit", pg. 2‐39).
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11. Transport
Suitable means of transportation are required to move the laser

device within the building or on the premises:
■ Pallet jack
■ Forklift truck
■ Castors (for local moving of the laser device)
11.1 Transport by means of pallet jack
Conditions
■ To move the laser device at the installation site:
− turn the laser device off.
− install the laser light cables and supply lines in a way
that there is enough space to move.
− ensure that the laser light cables and supply lines will not
be damaged.
■ To change the installation site of the laser device:
− all lines that run from other devices to the laser device
(e.g. from external control units) must be disconnected.
− The laser device must be disconnected from the electrical
mains.
− All laser light cables must be separated from the laser
device.
− completely empty the cooling unit if temperatures below
0 °C are to be expected during the transport or storage
For emptying the cooling unit a compressed air connec-
tion is required.
The chapter "Maintenance" contains a description for
emptying the laser cooler.
Note
For the transport of the laser device, a pallet jack is necessary.
One person is necessary to operate the pallet jack and to move
the laser device.
Minimum load capacity of the lift truck: 5 kN (500 kg).
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2018-04 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. 2-33
1. Inserting the pallet jack
Note
Avoid an inclination of more than 10° when transporting the
laser device.
2. Lift the laser device by means of the lift truck.
3. Secure the laser device by means of a belt against sliding.
4. Move the lift truck with the laser device slowly to the destina-
tion so that it can be stopped at any moment.
5. Carefully put the laser device down at its destination.
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Fig. 2-34
6. Fix the brakes of all 4 rollers.
11.2 Transporting by fork lift
Condition
■ Before transport with the forklift truck:
− all lines that run from other devices to the laser device
(e.g. from external control units) must be disconnected.
− The laser device must be disconnected from the electrical
mains.
device.
For emptying the cooling unit a compressed air connec-
tion is required.
Minimum carrying capacity of the fork lift truck: 5 kN (500 kg).
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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 trained person-
nel.
Ø Observe the safety regulations for the transport means.
1 Guide plate (2x) 2 Lifting fork (2x)

Fig. 2-35
1. Set the distance between the forks to 730 mm.

2. Place a protective mat over the laser device to protect the
side of the laser device facing the forklift truck.
Note
Avoid an inclination of more than 10° when transporting the
laser device.
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1 Laser device 3 Protection mat
2 Belt
Fig. 2-36
3. Carefully lift up the laser device using the fork lift truck.
4. Secure the laser device by means of a belt against sliding.
5. When driving, the following must be avoided:
− Fast cornering.
− Abrupt starting and stopping.
6. Carefully put the laser device down at its destination.
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Fig. 2-37
11.3 Moving the laser device on wheels
On horizontal surfaces the laser device can be moved using the

optionally attached castors. The castors are not intended for the
in-house transport but only for local moving of the laser device
at its installation site.
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Conditions
■ To move the laser device at the installation site:
− turn the laser device off.
− install the laser light cables and supply lines in a way
that there is enough space to move.
− ensure that the laser light cables and supply lines will not
be damaged.
■ To change the installation site of the laser device:
− Disconnect all lines that run from other devices to the
laser device (e.g. from the power supply or from external
control units).
device.
Fig. 2-38
1. Disengage the brakes on all 4 rollers.
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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. Move the laser device.
Fig. 2-39
11.4 Packing the laser device
Means, Tools, Materials

■ Wooden box for transport, material no. 2165138.
■ Stretch film.
■ Bubble wrap.
■ Aluminum composite hood, material no. 2014830.
■ Torx screws T20 60 mm.
■ Adhesive tape.
■ 3 x Hard foam panel.
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■ 2 x hard foam strips.
■ 4 x Anti-skid mat.
■ 3 x air cushions 600 mm x 900 mm.
■ 2 x Plywood panel.
■ 5 x beams.
■ 2 x shutter cooling water connections.
Preparations 1. Switching off the laser device (see chapter "Operating").

2. Emptying the cooling unit (see chapter "Maintenance").
3. Disconnect all electric connections from the laser device.
4. Disconnect laser light cable (see chapter " Maintenance").
Packing
Fig. 2-40
5. Put a hood of bubble wrap (2) over the laser device.
6. Roll up mains cable (1) (option) and attach it to side wall.
7. Seal cooling water connections (3) 2 x.
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Fig. 2-41
8. Place a hard foam panel on the laser device.
Fig. 2-42
9. Place aluminum composite hood (1) over the laser device
and wrap it in stretch wrap film (2).
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Fig. 2-43
10. Attach the side walls (1).
11. Attach hard foam strips (2) to the rear wall.
12. Place 2 hard foam panels (5) on the floor.
13. Put the plywood panel (4) onto the hard foam panels.
14. Place the beam (6) on the plywood board.
15. Place 2 anti-slip mats (3) on the press beams.
Fig. 2-44
16. Place laser device in the transport box.
17. Protect the laser device with press beams (5) from slipping.
18. Attach air cushions (4) between the laser device and the
side walls.
19. Keep a plywood board (1), 2 beams (2) and air cushions (3)
ready at hand.
20. Attach front wall of the transport box.
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Top view Fig. 2-45
21. Place plywood board (1) on the laser device.
22. Place cross beams (2) on the plywood board.
23. Screw cross beam together with front wall (4).
24. Screw cross beam together with front wall.
25. Attach air cushion (3) between front wall and laser device.
26. Fit cover on transport box.
Fig. 2-46
27. Attach tightening straps.
28. Mark the packaging:
"Transport in upright position only!"
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Chapter 3
Description
1 Overview 3‐3
2 Laser 3‐5
2.1 Structure 3‐5
2.2 Specifications 3‐5
3 Optical arrangement 3‐8

3.1 Components of the optical arrangement 3‐11
Shutter switch 3‐11
Shutter switch (VW1, VW2, ...) with pilot 3‐12
laser
Deflection (U1, U2, ...) 3‐15
3.3 Wedge beam switch (option) 3‐17
3.4 Switch can be adjusted by motor for BrightLine 3‐18
Weld (option)
3.5 Incoupling optics 3‐20
Incoupling optics LLK-D 3‐21
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2018-04 Description 3‐1
Laser light cable 3‐21
4 Diode power supply 3‐26
5 Control 3‐28
6 Mains distribution 3‐30
8 Cabinet cooler 3‐34
9 Recirculating air dryer system (RDS) 3‐35
10 Panel computer (option) 3‐37
11 Telepresence 3‐38
11.1 Connection via VPN TRUMPF to the laser 3‐38
device
11.2 Connection via VPN laser device to TRUMPF 3‐39
11.3 Connection via SSH 3‐39
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1. Overview
1 Optical arrangement 5 Space for interfaces 9 Mains distribution (MDI)

2 Laser 6 Cabinet cooler 10 Recirculation air dryer system
3 Incoupling optics 7 Diode power supply (DPS20) (RDS2)
4 Separation wall to heat 8 Frequency converter 11 Control
exchanger 12 Panel computer (Option)
Fig. 3-1
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2018-04 Overview 3‐3
1 Laser cooler 3 Focusing optics 4 Laser light cable
2 Cabinet cooler
Fig. 3-2
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2. Laser
1 Rear mirrors 4 Pump unit

2 Folding mirror, fixed 5 Cavity
3 Folding mirror, adjustable 6 output coupling mirror
Fitting position of the laser Fig. 3-3
2.1 Structure
The main components of the laser are:

■ Pump unit.
■ Cavity with laser disk.
■ Resonator, comprising two folding mirrors, rear mirror and
output coupling mirror.
The output coupling mirror is partially transmitting for laser light.
The cavity, the pump unit and the mirror holder are cooled with
deionized water.
2.2 Specifications
TruDisk 3000 Wavelength of the laser light 1030 nm

Minimum laser power 80 W
Maximum laser power 3000 W
Beam parameter product 2 mm·mrad
Tab. 3-1
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2018-04 Laser 3‐5
Tab. 3-2

Tab. 3-3

Tab. 3-4

Beam parameter product 2.5 mm·mrad
Tab. 3-5

Tab. 3-6

Tab. 3-7

Tab. 3-8

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Tab. 3-9

Tab. 3-10

Tab. 3-11

Tab. 3-12

Tab. 3-13

Tab. 3-14
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2018-04 Laser 3‐7
3. Optical arrangement
Fig. 3-4
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.
Between the components there are metal beam guard elements
with 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. This variant of the optical arrangement
allows the guiding of the laser light cable into one or two proc-
essing stations.
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 "Com-
ponents of the optical arrangement", pg. 3‐11).
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1 Incoupling optics 5 Deflection for absorber 8 Plasma sensor (option)
2 Laser light cable 6 Shutter switches 9 Beam guard
3 Beam guideway aperture 7 Deflection 90° 10 Wedge beam switch (option)
4 Absorber
Optical arrangement (example) Fig. 3-5
The laser light is fed in at the point to which the arrow desig-
nated “LASER” is pointing.
In a deflection, the laser light is deflected by 90° to the left to
the first shutter switch (VW).
The positions of the shutter switches VW determine to which
light path the laser light is guided.
The following picture shows a variant of the optical arrangement
that allows a retrofitting of one outlet without converting the exist-
ing shutter switch.
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2018-04 Optical arrangement 3‐9
Fig. 3-6
The following picture shows a variant of the optical arrangement

in which both laser light cables are guided into one processing
station. The two shutter switches are connected to the
ASV3_Twin board.
Fig. 3-7
The following picture shows a variant of the optic arrangment in

which each laser light cable is guided into a separate processing
station. Each shutter switch is connected to an ASV3 LLKM
board.

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Fig. 3-8
3.1 Components of the optical

arrangement
Shutter switch
1 Mirror moved out of beam 3 Mirror in the beam guideway 4 Laser beam is deflected by 90°
guideway
2 Laser beam passes through in
a straight line
Fig. 3-9
With a shutter switch, the laser beam can optionally be deflected

in one of two directions.
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If the mirror is in the beam guideway, the laser beam is
deflected by 90° (picture B). If the beam is swiveled out of the
beam guideway, the laser beam passes through the shutter
switch in a straight line (picture A).
Shutter switch (VW1, VW2, ...) with pilot

laser
1 Pilot laser 3 Pilot laser beam

2 Shutter switch mirror
Fig. 3-10
The shutter switch enclosure with pilot laser contains a semi-con-

ductor laser is (1). The semiconductor laser functions as a pilot
laser for the light path to which the shutter switch is assigned.
Advantage The pilot laser in the shutter switch can be used while the work-
ing laser light is guided to a different light path. This allows to
use the pilot laser at processing point while workpieces are
machined at a different point.
Activate 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. 3-11", pg. 3‐14)).
To switch on the pilot laser on the user interface is described in
chapter "Operating".
Laser classes The pilot laser has been classified as a Class 3Rcomponent.
This must be taken into account during operation, for example
by the service personnel, after removal from the unit.
In standard operation, the pilot laser light emitted from the
focussing optics outlet corresponds to class 1.

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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 shutter
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.
3-11", pg. 3‐14) (picture A). This also happens if a different
command comes from the operator or from a running laser pro-
gram.
Information about the operating principle and wiring of the safety
circuit is to be found in the interface description “ASV safety cir-
cuit”.
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. 3-11", 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.
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A VW1 and VW2 closed B VW1 open C VW2 open
Fig. 3-11

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Deflection (U1, U2, ...)
Fig. 3-12
The deflection deflects the laser beam by 90° to the right or to

the left.
3.2 Selecting a 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.
Light path determined by VW2 Fig. 3-13
In this figure, the mirror of the shutter switch VW2 has been
swiveled into the beam guideway. At this point, the laser beam is
deflected through 90° and coupled into the laser light cable con-
nected to this light path.
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Light path determined by VW1 Fig. 3-14
In this figure, the mirror of the shutter switch VW1 has been
swiveled into the beam guideway. At this point, the laser beam is
deflected through 90° and coupled into the laser light cable con-
nected to this light path.
Light path in the absorber Fig. 3-15
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):
■ Using software interface of the laser device (see chapter
"Operation").
■ in laser programs (see chapter "Operation").

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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 the laser

output it is possible, in conjunction with a 2-in-1 LLK, to select
the core diameter of the LLK through which the laser light will be
guided 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.
1 Laser beam in the inner core 2 Laser beam in the outer core
Fig. 3-16
The following picture shows a wedge beam switch and its com-
ponents.
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1 LED is lit, wedge in beam 6 Proximity switch, wedge out of
guideway beam guideway
2 LED is lit, wedge out of beam 7 Proximity switch, wedge in
guideway beam guideway
3 Stepping motor 8 Wedge
4 Tension spring 9 SIO3 board
5 Switching cam
Fig. 3-17
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 (2) lights up.
■ 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 (1) lights up.
3.4 Switch can be adjusted by motor for

BrightLine Weld (option)
The switch can be used optionally in optical arrangements of

specific laser devices.
The switch is used together with a 2-in-1 LLK. The laser light
can be guided to the focusing optics by adjusting a wedge in the

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switch in the inner core, the outer core, or proportionately via the
inner and outer core at the same time.
1 100% of laser light in inner 3 Laser light flexibly distributed

core between the inner and outer
2 100% of laser light in outer core
core
View cross-section double-core optical fiber Fig. 3-18
This means that there are three applications at one laser output:
■ Cutting: 100% of the laser light in the inner core of the 2-in-1
LLK.
■ Welding: 100% of the laser light in the outer core of the 2-
in-1 LLKs.
■ Spatter-reduced welding "BrightLine Weld": laser light flexibly
distributed between the inner and outer core of the 2-in-1
LLK.
Example switch 0° 0.3° motor-adjustable RD (FCM) Fig. 3-19
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3.5 Incoupling optics
Fig. 3-20
The incoupling optics contains a lens which focuses the laser

beam to the beginning of the light guide in the laser light cable.

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Incoupling optics LLK-D
Fig. 3-21
Laser light cable
Fig. 3-22
Purpose The laser light cable is a flexible transmission means for laser
light. It enables the spatial separation between laser and proc-
essing station.
Structure In the interior of the laser light cable there is a light guide which
guides the laser beam from the laser device to the focusing
optics. The light guide is surrounded by a plastic hose and a
steel sheath. The steel housing protects the light guide from
mechanical stress. It limits the bending radius of the laser light
cable.
The steel sheath is surrounded by an external plastic hose which
protects the laser light cable against environmental effects.
A safety device integrated into the laser light cable switches the
laser automatically off if the light guide is damaged or the laser
light cable at the laser or at the focusing optics is pulled out.
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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
LLK length with restrictions TruDisk 3000, TruDisk 4000:
LLK-HP 50 µm to 50 m
TruDisk 3001: 75 µm to 40 m
TruDisk 4001: 75 µm to 30 m,
100 µm to 50 m,
200 µm to 70 m
200 µm to 50 m,
300/400 µm to 70 m
150 µm to 30 m,
200 µm to 40 m,
300/400 µm to 50 m
Min. permissible bending radius 200 mm
Cable diameter 13 mm
Fiber core diameter TruDisk 3000, TruDisk 4000:
LLK-HP 50 µm
75 µm, 100 µm, 200 µm,
300 µm, 400 µm, 600 µm
100 µm, 150 µm, 200 µm,
300 µm, 400 µm, 600 µm
200 µm, 300 µm, 400 µm,
600 µm
600 µm
Possible combinations of different 100 μm / 400 μm
fiber core sizes of dual-core laser 100 μm / 600 μm
light cables
Tab. 3-15
Only splice LLKs are approved for the individual laser types. The
following figure shows which characteristics can be used to rec-
ognize a splice LLK (SPL).
Characteristics of splice LLKs on LLK plug on laser side Fig. 3-23

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WS-71081
1 Protective glass 4 Cooling water connection plug
2 Optical plug, laser side cooling
3 Electrical plug, monitoring 5 Cable
6 Optical plug, machining side
Laser light cable, components Fig. 3-24
Monitoring The laser light cable is monitored over the whole length. The
laser device switches off immediately and no more laser light
can be emitted if a fault occurs in the laser light cable.
The fit of both optical plugs is monitored. If an optical plug is
loosened, the laser device immediately switches off.
The electrical plug is connected to the laser light cable monitor-
ing of the laser control.
Laying the laser light cable Laser light cables must be permanently installed outside the
laser safety cabins.
To do so, use:
■ Cable clips
■ Cable ducts
■ Other appropriate auxiliaries for fastening cables.
Laser light cables can be laid freely and loosely inside of the
laser cabins which are monitored by a safety circuit.
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3.6 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.

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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 Counter ring 8 Eyepiece
Focusing optics (Example for welding) Fig. 3-26
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4. Diode power supply
Fig. 3-27
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 signal sequence of the laser power is ach-
ieved.
The control unit constantly monitors the diode power supply.
Operational values and statuses of the diode power supplies can
be displayed in TruControl (Main operation> Diagnose).
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1 Hole for fastening (2x) 10 Connection: cooling water sup-
2 X20: Connector current output ply
1 11 Connection: cooling water
3 X21: Connector current output return
2 12 X1: Connector for the mains
4 Handle connection
5 Coax-measurement connector, 13 LED status error (red) and
signals selectable using soft- diag. (green)
ware 14 X33: CAN bus connector
6 X22: Connector current output 15 X3: CAN bus connector
3 16 Address switch for CAN bus
7 X4: Connectors 24°V°DC and 17 Connector for test and diagno-
EPE control signals sis
8 4 status LEDs: +15 V, -15 V,
EPE and ENABLE converter
(safety functionality)
9 X23: Connector current output
4
Fig. 3-28
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2018-04 Diode power supply 3‐27
5. Control
Fig. 3-29
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 on this topic is given in the chapter "Installation con-
ditions" and in the interface descriptions.
Drive The most important functions are:

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

unit generates a monitoring message or a fault message.
The message is displayed on the screen. If a malfunction
occurs, the control unit stops the operation of the laser until the
cause of the malfunction is eliminated.
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Composition
1 PBT (voltage supply) 4 DLCD_V4E (Digital Laser Con- 7 IIO3 (Interface Intelligent Optics)
2 CPX-V4 (central processor) trol, version V4E) 8 SW4 (beam switch) (option for
3 Slot for field bus module 5 ISA (Interface Scanner Analog) wedge beam switch)
6 ASV3 LLKM (safety circuit and 9 ICF (Interface CAN Fluores-
LLK monitoring) cence)
Example: Laser control for 1 laser outlet Fig. 3-30
The control is composed of individual electronic components.

The component parts of the control can differ from the figure.
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2018-04 Control 3‐29
6. Mains distribution
Fig. 3-31
The mains distributor distributes the electrical energy to the indi-

vidual consuming components in the laser device.
Detailed information about the mains distribution can be found in
the circuit documents.
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1 Main switch 7 CMD board 12 Control power supply -24 V
2 Power circuit breaker for diode 8 PSB board (optional)
power supply 9 Frequency converter LCO 13 Control power supply +24 V (3x)
3 Circuit breaker power supply 10 EMERGENCY STOP relays 14 Mains lead
4 EMERGENCY STOP interface 11 24 V Versorgung Panel-PC 15 Line filter
5 Switch-on port (Option) 16 Contactor for diode power sup-
6 Electric fuses 24 V ply
Fig. 3-32
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2018-04 Mains distribution 3‐31
7. Laser cooler
Fig. 3-33
The laser cooler dissipates the heat arising in the laser through
a heat exchanger to an external cooling circuit.
If the supply temperature in the external cooling circuit exceeds
a certain value or the minimum pressure in the supply is no lon-
ger reached, an external chiller must be used in addition. You
will find the corresponding technical information in the chapter
“Installation conditions, Transport”.
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1 Control board CCB 4 Motor valve 6 Pump
2 Tank 5 Fine filter 7 Contamination filter
3 Heat exchanger
Fig. 3-34
The laser is cooled with cooling water. The pump delivers the
cooling water from the tank via the supply distributor to the
cooled components:
■ Pump unit and other cooled components of the laser
■ Absorber and other cooled components of the optical
arrangement.
■ Focusing optics.
■ Diode power 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.
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2018-04 Laser cooler 3‐33
8. Cabinet cooler
Fig. 3-35
The cabinet cooler dissipates the heat produced in the interior of

the laser device through a heat exchanger to the laser cooling
circuit. In this way, the temperature in the cabinet is cooled to a
certain value and is thus independent of the ambient tempera-
ture.
1 Heat exchanger 3 Fan

2 Connections of the laser cool-
ing circuit
Components of the cabinet cooler Fig. 3-36
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9. Recirculating air dryer system (RDS)
Fig. 3-37
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2018-04 Recirculating air dryer system (RDS) 3‐35
1 Drying air, supply 7 Temperature and humidity sen- 12 Outlet valve
2 Drying air, return sor 13 Connection for air inlet
3 Fastening screws (2x) 8 Fan module 14 Connection for blower module
4 Blower unit 9 Pressure sensor 15 Connection for pressure sensor
5 Moisture separator 10 Control board (CRDS) 16 Filter module
6 Connection, air outlet 11 Connection, air inlet
Fig. 3-38
The recirculating air dryer system dries and cleans the recirculat-
ing air, which in turn dries the components of the resonator, the
optical arrangement and of the pump unit. A small part of the
recirculating is replaced with new air from the environment. The
remaining air remains in circulation.
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10. Panel computer (option)
Fig. 3-39
Your laser device can be operated via a panel computer. The

program TruControl 1000 Module Remote to control the laser
device is installed on the panel computer.
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2018-04 Panel computer (option) 3‐37
11. Telepresence
What does teleservice Teleservice 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.
■ Display operating values.
■ Troubleshooting.
■ Read out operation data and transfer it to TRUMPF.
■ Change setting values.
■ Update the software.
Support provided by With Teleservice, TRUMPF can assist you in:

TRUMPF ■ using the laser device most efficiently for your application.
■ recognizing the necessity of preventive maintenance.
■ locating faults very quickly and taking the appropriate steps
for their elimination.
■ 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).
11.1 Connection via VPN TRUMPF to the

laser device
The establishment of the Virtual Private Network (VPN) connec-

tion is arranged by the TRUMPF subsidiary.
For further information regarding the connection via VPN, refer to
the technical information "VPN connection".
The access via a Virtual Private Network (VPN) can be carried

out in the following ways:
■ VPN via internet
■ Special connection as defined by the customer
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Required information TRUMPF requires the following information to ensure connection
via VPN:
■ IP address of the VPN connection.
■ user name and password of the access autorization.
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.
■ device number of the laser devices from TRUMPF.
■ IP address of the laser device from TRUMPF.
■ name of the contact person for the laser device.
■ telephone number for questions.
11.2 Connection via VPN laser device to

TRUMPF
The VPN link setup is initiated by the laser device. The software
tool Request service is an extension of the TRUMPF TelePre-
sence Portal. This tool can be used to establish a connection to
the TRUMPF TelePresence Portal in order to allow a service
technician of TRUMPF a remote access to the laser device. The
Request service function is safe and protected by a firewall. In
the software manual "TruControl 1000" (10-06-80-A1-CR), chap-
ter "Service", you will find further information on the Request
service function.
11.3 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 "Teleservice 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.
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2018-04 Telepresence 3‐39
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).
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Chapter 4
Operating
1 Operation and display elements 4‐3

1.1 Housing 4‐3
1.2 PC with Windows and software TruControl 4‐5
Module Remote
1.3 Computer panel (option) 4‐5
2 Switching the laser device on and off 4‐6

2.1 Switching on at the case with switches 4‐6
2.2 Switching on with panel computer or Windows 4‐7
PC
2.3 Switching off in case of emergency or malfunc- 4‐8
tion
2.4 Switching on after E-STOP 4‐8
2.5 Switching off at the case with switches 4‐8
2.6 Switching off after work completion with the 4‐9
panel computer or the Windows PC
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2018-04 Operating 4‐1
3 Operating a laser device using TruCon- 4‐11
trol 1000
3.1 Responding to messages 4‐11
Resetting the message 4‐12
Select the light path in the parameter set 4‐12
Changing the light path name 4‐14
3.3 Activating and deactivating the laser 4‐15
Switching the laser on and off 4‐15
3.4 Creating pulse shapes 4‐16
3.5 Creating laser programs 4‐17
3.6 Editing light paths 4‐17
3.7 Pilot laser 4‐18
Switching the switching functions of pilot 4‐18
laser on and off
Setting the pilot laser mode 4‐19
Switching the pilot laser on and off in the 4‐21
light path
4 Controlling the laser device from outside 4‐24

4.1 TRUMPF LaserNetwork (option) 4‐24
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1. Operation and display elements
1.1 Housing
1 Main switch 4 Indicator light "Monitoring"

2 EMERGENCY STOP push-but- 5 Laser warning lamp
ton (option) 6 Key-operated switch
3 ON/OFF button with signal
lamp
Fig. 4-1
EMERGENCY STOP push- The laser is switched off immediately if the EMERGENCY STOP
button (option) push-button is pressed. In particular, no more laser light is emit-
ted.
The EMERGENCY STOP push-button can be integrated in the
EMERGENCY STOP circuit of a system. With this push-button,
the entire system can be cut off. More information can be found
in the interface description "EMERGENCY STOP".
Push-button ON/OFF with ON/OFF button:

indicator light ■ lights white when the laser device is supplied with line volt-
age and the main switch is in ON position.
■ flashes blue while the control unit is switched on.
■ lights blue if the control unit is on.
Indicator light "Monitoring" The indicator light "monitor" lights up when:

■ an operating value has exceeded the monitoring limit.
■ a malfunction has occurred.
■ the EMERGENCY STOP circuit has been interrupted.
If the “Monitoring” indicator lamp is lit, a message will be dis-
played. The message contains information about cause and trou-
bleshooting measures.
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2018-04 Operation and display elements 4‐3
Laser warning lamp The laser warning lamp is lit when:
■ laser light is emitted at the processing point.
■ the laser is ready for releasing laser light, even if no laser
light is emitted at the processing point yet (“laser on” status).
Key-operated switch
Fig. 4-2
The key-operated switch enables to prevent unauthorized

starting of the laser. For this purpose, the key must be brought
to position Laser locked (chart A) and be removed.
The key must be inserted during operation. The key-operated
switch must be turned to the position Release laser (chart B).
Main switch The main switch has 2 positions: ON and OFF.

To connect the laser device to the mains, position the main
switch to ON.
To disconnect the laser device from the mains, position the main
switch to OFF.
In OFF position:
■ the main switch disconnects the laser device from the mains.
■ the main switch can be protected against unauthorized
switching-on by means of padlocks.
Always protect the main switch against unauthorized switching-
on during maintenance and repair work.
Exceptions are allowed only:

■ if work is done by trained personnel or skilled electricians
and
■ if the work cannot be carried out with the laser device
switched off.
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1.2 PC with Windows and software
TruControl Module Remote
TruControl 1000 Module Remote is supplied on a CD-ROM. Tru-

Control 1000 Module Remote is a software for the remote
control of TruControl 1000 via a network.
1.3 Computer panel (option)
1 Touchscreen
Fig. 4-3
The panel computer is provided with a touchscreen. The screen

of the panel computer reacts to finger pressure. Software func-
tions, buttons and fields are selected by pressing the respective
point on the user interface with the finger. Mouse and keyboard
can be connected via a USB port. The panel computer is either
connected via a network or a cable directly to the central pro-
cessor (CPX) in the laser control of the laser device.
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2018-04 Operation and display elements 4‐5
2. Switching the laser device on and off
2.1 Switching on at the case with

switches
Condition
■ The following lines and cables are connected:
− Electrical mains connection.
− External cooling circuit.
− Laser light cable.
− Control lines between laser device and panel computer
or Windows PC, if applicable.
− Control lines to periphery, if applicable.
1. To activate the external cooling: Open valves in the supply

and return line of the external cooling circuit.
2. If a chiller is used: switch on chiller.
1 ON/OFF button with signal 3 Main switch

lamp
2 Key-operated switch
Fig. 4-4
3. Turn key switch (2) to the "Laser released" position.
4. Turn main switch (3) to the “ON” position.
5. Check whether the indicator lamp of the ON/OFF button (1)
lights white.
The indicator lamp of the ON/OFF button (1) lights white if
the laser device is connected to mains voltage.
6. Switch on the control unit of the laser device:
− Press the ON/OFF button (1) ≥ 1 s.
The indicator lamp of the ON/OFF button (1) flashes blue
while the control unit is switched on.
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7. Wait until the control is switched on.
The control unit is switched on when the indicator lamp of
the ON/OFF button (1) permanently flashes blue.
The laser device is now on.
2.2 Switching on with panel computer or

Windows PC
Condition
■ The following lines and cables are connected:
− Electrical mains connection.
− External cooling circuit.
− Laser light cable.
− Control lines between laser device and panel computer
or Windows PC.
− Control lines to periphery, if applicable.
1. To activate the external cooling: Open valves in the supply

and return line of the external cooling circuit.
2. If a chiller is used: switch on chiller.
3. Turn the key-operated switch to position Laser released.
4. Turn main switch of the laser device to the ON position.
The indicator lamp of the ON/OFF button (1) lights white if
the laser device is connected to mains voltage.
5. Switch on the control unit of the laser device:
− Press the ON/OFF button (1) ≥ 1 s.
while the control unit is switched on.
6. Wait until the control is switched on.
The control unit is switched on when the indicator lamp of
the ON/OFF button (1) permanently flashes blue.
7. Switch on panel computer.
or
Ø Start the TruControl 1000 Module Remote on the Win-
dows PC.
After a few seconds, the main screen of the TruControl 1000
program appears.
The laser device is now on.
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2018-04 Switching the laser device on and off 4‐7
2.3 Switching off in case of emergency
or malfunction
Ø Press the EMERGENCY STOP push-button on the front of

the laser device.
The laser is switched off. In particular, no laser light can be
emitted after the EMERGENCY STOP push-button has been
pressed.
The control unit of the laser device remains switched on.
The indicator lamp of the ON/OFF button permanently lights
blue.
The "Monitoring" indicator lamp lights white.
Tip
To switch the control unit off, press the ON/OFF button for > 4 s.
2.4 Switching on after E-STOP
1. Turn the pressed E-Stop push-button in direction of the

arrow.
The push-button is unlocked. Disabled functions of the laser
device are rendered ready for service.
2. Observe the monitoring and fault messages.
3. Eliminate the cause of faults (see chapter "What to do in
case of service interruptions").
4. In TruControl 1000, select manual mode and press the Reset
button.
or
Ø Activate the Reset via the external control.
The control unit is reset to original condition.
Laser device is again ready for operation.
2.5 Switching off at the case with

switches
Note
Always proceed in the indicated order since otherwise software
and hardware damage may occur in the control unit of the laser
device.

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1 ON/OFF button with signal 3 Main switch
lamp
2 Key-operated switch
Fig. 4-5
1. Press the ON/OFF button (1) on the front of the laser device
for > 4 s.
while the control unit is switched off.
2. Wait until the control unit of laser device is switched off.
The control unit is switched off when the indicator lamp of
the ON/OFF button (1) permanently lights white.
3. Turn the main switch (3) of the laser device to the OFF posi-
tion.
4. Turn the key switch (2) to the left and remove the key.
The laser device is switched off.
2.6 Switching off after work completion

with the panel computer or the
Windows PC
Note
Always proceed in the indicated order since otherwise software
and hardware damage may occur in the control unit of the laser
device.
Switching off the laser 1. Press the ON/OFF button (1) on the front of the laser device
device for > 4 s.
while the control unit is switched off.
2. Wait until the control unit of laser device is switched off.
The control unit is switched off when the indicator lamp of
the ON/OFF button (1) permanently lights white.
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2018-04 Switching the laser device on and off 4‐9
3. Turn the main switch of the laser device to the OFF position.
4. Turn the key-operated switch to the left and remove the key.
5. Switch off the panel computer.
or
Ø Quit the TruControl 1000 Module Remote on the Win-
dows PC.
The laser device is switched off.

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

TruControl 1000 program for operation of the laser device.
The software manual TruControl 1000 contains further informa-
tion.
3.1 Responding to messages
The control unit monitors numerous operational values of your

laser device.
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.
Icon Explanation
Icon for fault message
Icon for monitoring message
Tab. 4-1
The message line displays the message code and the short text
of the message.
1 Icon of the message 3 Message line

2 Message code and short text
Fig. 4-6
A fault message is displayed as soon as a monitored opera-

tional value is out of the permissible range and, thus, causes a
critical condition.
The laser is deactivated if a fault message is displayed. It cannot
be switched on again until the cause for the critical condition has
been eliminated.
For further information about messages, please refer to chapter
"What to do in case of service interruptions" and the software
manual TruControl 1000.
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2018-04 Operating a laser device using TruControl 1000 4‐11
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: switching
on and test sequences are carried out until the laser device is
ready again.
Ø Either
Ø Select the Diagnostics main operation.
Ø Select the message history with .
Ø Select the Reset button.
or
Ø Select message line.
Ø Select the >Message tab.
Ø Press Reset to reset the fault message.
The message is reset.
3.2 Selecting a light path
The optical arrangement of the laser device mostly allows you to

select from several laser light cables through which the laser
light can be conducted to the processing 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
Condition
■ No external control is active.
1. Select main operation Manual operation.

2. Select the Pulse data tab.
3. Open the parameter set using .
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Fig. 4-7
4. Selecting a 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 the
next time the laser is triggered.
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Changing the light path name
Condition
■ User level ≥ 60
Fig. 4-8
1. Select the main operation Technology(1-2).

2. Select the Light path tab.
3. Mark the light path (3).
4. Select Change (4).
The Edit light path dialog is displayed.
5. Press the Change name button (5).
The screen keyboard is displayed.
6. Enter a name and press the Finish button (6).
7. Select Save (7).
The name of the light path is changed.

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3.3 Activating and deactivating the laser
Switching the laser on and off
Conditions
■ The laser device has been switched on.
■ The buttonLaser is active on the touchscreen of the operat-
ing panel.
■ There is no active fault message.
■ The parameter set or the laser program has been selected.
1. Select main operation Manual operation.

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.
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 your eyes.
Ø Do not reach between focusing optics and workpiece.
Ø Wear laser safety glasses suitable for the wavelength of the
laser light (see notice signs).
5. Select Trigger.
The Release button changes its color from gray to yellow.
With the Release button, a laser program or parameter set is
started.
The button Release causes the generation of laser light or
the start of a laser program.
6. Select Stop.
The Stop button changes the color from yellow to grey.
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.
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3.4 Creating pulse shapes
The laser device can create any pulse shapes wanted. A pulse
shape editor is integrated in TruControl 1000. Pulse shapes are
created, edited and managed in the pulse shape editor.
1 Title bar 3 Option for changing the time dif- 5 Pulse shape diagram
2 Pulse data table ference
4 Context bar
Pulse shape editor Fig. 4-9
The power points of the pulse shapes can be entered graphically

or by means of a table.
Pulse shapes can be:

■ embedded in parameter sets and in laser programs.
■ statical or scalable.
■ Applied as a reference in a parameter set.
■ transferred as reference or as copy in a laser program.
■ saved as templates.
Information on pulse shapes and operation of the pulse shape
editor is given in TruControl 1000 software manual.

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3.5 Creating laser programs
A laser program is a sequence of commands and settings exe-

cuted automatically after start.
A laser program editor is integrated in TruControl 1000. Laser
programs are created, edited and managed in the laser program
editor.
Laser programs can be called:

■ manually.
■ externally via a laser device interface.
Fig. 4-10
Laser programs are composed of program lines.

Information on operation of the laser program editor is given in
the TruControl 1000 software manual.
3.6 Editing light paths
Possible actions In connection with light paths, the following actions are possible
under TruControl 1000:
■ Display details on light paths
■ Display light path overview
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■ Change light path name
■ Log the focusing optics on and off
Please refer to the software manual TruControl 1000 for further
information on authorization and processing.
Programming light paths TRUMPF has already programmed all possible light paths for the
optical arrangement of your laser device. Programming light
paths should be done exclusively by the TRUMPF Laser service
engineers (from user level 70). This is only necessary if the opti-
cal 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
A pilot laser is provided in the laser device and sends visible,

red light with low power through the beam guideway. In this way
it is possible to observe the light path and the processes at the
processing point. If the pilot laser is switched on, the icon for the
pilot laser is displayed in the status bar.
Fig. 4-11
Activate pilot laser When the pilot laser is switched on, is determined:
■ by the pilot laser mode set in the system settings (see "Set-
ting the pilot laser mode", pg. 4‐19).
■ by the shutter switch state (shutter switch closed or open).
■ by the state of the safety circuit (safety circuit interrupted or
closed).
■ by the PILOT_LASER_ON external signal.
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 is 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 on and off in the light path", pg. 4‐21).
1. Select main operation Setup.

2. Use to select Switching functions.

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3. Tick the check box Activate pilot laser.
The pilot laser is switched on. 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 irrespectively of the set pilot laser
mode if the single-channel and double-channel safety circuits
(ASV3, connectors X24, X25) are used for internal functions (e.g.
protection of the laser light cables in the user's compartment)
and as soon as the single-channel and double-channel safety
circuits are interrupted.
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Fig. 4-12
1. Select the main activity Setup.(1-2).

2. Open by pressing Open system settings (3-4).
3. Mark "PilotLaserMode" signal (5).
4. Select Change (6).
5. Select 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.

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Mode Meaning
3 The pilot laser is on, as soon as
■ its switching functions have been switched on. (see "Switch-
ing the switching functions of the pilot laser on and off")
OR
■ External signal PILOT_LASER_ON is set.
■ AND
Shutter switch closed.
4 ■ its switching functions have been switched on. (see "Switch-
OR
■ AND
the safety circuit is interrupted.
5 The pilot laser is on, as soon as
■ its switching functions have been switched on. (see "Switch-
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 (e.g. protection of the laser light
cables in the user's compartment)
AND
the single-channel safety circuit is interrupted.
Tab. 4-2
6. Select Apply.
The pilot laser mode has been set.
Switching the pilot laser on and off in the

light path
In the light path overview, the user can switch the pilot laser for
the individual light paths on and off.
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Fig. 4-13
1. Select the main operation Production(1-2).

2. Use to open the light path overview (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 Pilot laser overview. Fig. 4-14

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4. Switch on the pilot laser in the corresponding light path by
means of .
or
Ø Switch off the pilot laser in the corresponding light path
by means of .
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4. Controlling the laser device from
outside
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 provides the possibility to connect up to

32 external controls to the laser device and to control the laser.
The external control units are connected with the laser device
through fieldbus 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:

■ Coding of light paths.
■ Double channel safety circuits.
Ethernet Via Ethernet the laser device can be connected with other devi-
ces in a local network (LAN).
Detailed information can be found in the Technical Information
TRUMPF LaserNetwork and other documents available from
TRUMPF.
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Chapter 5
Maintenance
1 General notes 5‐3
2 Material 5‐4
2.1 Cooling water additives 5‐4
2.2 Tools and additional equipment 5‐4
Blow-out device 5‐6
2.3 Consumables 5‐7
2.4 Disposal 5‐7
3 Opening and closing the laser device 5‐8

3.1 Opening and closing doors 5‐8
3.2 Removing covers 5‐8
3.3 Open and close hood 5‐9
4 Hose connections 5‐10

4.1 Connecting the hose 5‐10
4.2 Disconnecting the hose 5‐10
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2018-04 Maintenance 5‐1
5 Operating mode 5‐11
5.1 Activating the operating mode TRUMPF main- 5‐11
tenance
6 Laser light cable 5‐14

6.1 Dismounting and mounting the laser light cable 5‐14
Removing LLK-D 5‐14
Mounting the LLK-D 5‐22
6.2 Maintaining laser light cable 5‐30
Replacing the protective sleeve with protec- 5‐30
tive glass at the LLK-D
7 Diode power supply (DPS) 5‐34

7.1 Replacing the diode power supply (DPS) 5‐35

8.1 Filling the cooling unit 5‐43
8.2 Emptying the cooling unit 5‐48
8.3 Cleaning the contamination filter 5‐67
8.4 Replacing filter element in the fine filter 5‐71
8.5 Cleaning the laser circuit 5‐73
Carrying out cleaning cycle and cooling 5‐75
water replacement
8.6 Refill the cooling water 5‐87
8.7 Checking the tightness of cooling unit 5‐89
9 Electrics 5‐91
9.1 Identifying blown electrical fuses 5‐91
9.2 Replacing the microfuse 5‐93
9.3 Activating the power circuit breaker 5‐94
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1. General notes
Appropriate maintenance is an important prerequisite for trouble-

free operation of the laser device and the quality of the work
results.
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 the condition of your laser device regularly. Carry out
maintenance tasks as a precautionary measure if you detect
signs of wear or contamination.
Check the laser light cable regularly for damaged shell. The
laser light cable must be replaced in case of a damaged shell.
While carrying out maintenance work on the laser device

DANGER you may have to deal with parts dangerous for persons and
material.
Improper or incautious procedures can cause injuries or
damages to property.
Ø Maintenance work may be carried out by trained personnel
only.
Ø Any work at the electrical equipment may only be performed
by a skilled electrician.
Ø Always observe the warning notes in these maintenance
instructions.
Ø Switch off the laser device before starting maintenance work.
Note
The laser device must be switched on during maintenance work
only if it is necessary for maintenance or control purposes. You
are informed about this in the corresponding passages of this
manual.
Help when problems arise Contact the TRUMPF service department, if there are any prob-
lems you cannot resolve. The service address can be found at
the beginning of the operating instructions.
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2018-04 General notes 5‐3
2. Material
Assembly Designation Material No. Recom-

mended
stock
Cooling unit Filter in tank 1224876 1
Filter element in the 1888631 1
fine filter
Set of wearing parts 1768532 1
for contamination fil-
ter
Electrics Locking set 2043866 1
Tab. 5-1
2.1 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.
2.2 Tools and additional equipment
Symbol Designation Dimensions, other data

Cabinet key for opening the doors and the hoods
Slotted screwdriver 2.5 mm, 3 mm
Cross-tip screwdriver PH1, PH2
Hexagon screwdriver 4 mm, 5 mm
Torx screwdriver T25, T30
5‐4 Material 2018-04 20-10-06-A3001-

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Symbol Designation Dimensions, other data
Torque screwdriver 250 Ncm
to tighten the protection sleeve with
protective glass
Material No.: 1533390
Open-end wrench 9 mm, 19 mm, 30 mm
Pan for cooling water
Cleaning cloth to wipe up drained water
Protective gloves rubber, to be worn when handling

deionized water
Cleaning brushes Soft bristles
Clean water can made of plastic to fill the tank of the laser cooling
material unit
Tools and auxiliary tools for maintenance Tab. 5-3
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2018-04 Material 5‐5
Blow-out device
SR-03378
Fig. 5-1
The blow-out device is an auxiliary tool for emptying the laser

cooler. The blow-out device can be ordered from TRUMPF,
Material No.: 2087242.
Compressed air instructions To operate the blow-out device, compressed air of quality class 3
according to DIN ISO 8573-1 is required (see the table).
Permitted pressure range: ≥ 2 bar and ≤ 6 bar.
Volume flow rate: ≥ 500 l/min.
Substance of contents Class according to Limit value

DIN ISO 8573-1
Dust 3 Particle size : < 5 µm
Particle density: < 500 pro m3
Pressure dew point 3 -20 °C
Oil 3 < 1 mg/m³
Tab. 5-4
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2.3 Consumables
For maintenance work on your laser device you need the follow-
ing extras:
■ Lens cleaning paper or cotton wool to clean optical glasses
(available from the photo shops).
■ Deionized water (DI water) as cooling water for the internal
laser cooler circuit. The required quantity is indicated. Water
with drink water quality must be used for the procurement of
DI-water.
■ 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 open fire and other ignition sour-
ces.
Ø Do not smoke.
Ø Supply sufficient fresh air.
Ø Do not inhale methanol vapor.
2.4 Disposal
Some maintenance work will produce waste material that must

be disposed of. Instructions for an appropriate disposal are given
in the corresponding sections.
The instructions for disposal of waste material are recommenda-
tions, derived from regulations applied at the place and time
when these operating instructions were issued. 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 protec- Residual waste

tive glass
Seals, O-rings Residual waste
Lens cleaning paper Residual waste
Cooling water without addi- Sewage system
tives
Filter materials Residual waste
Electric fuses Residual waste
Tab. 5-5
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2018-04 Material 5‐7
3. Opening and closing the laser device
Dangerous electric voltage inside the laser device!

DANGER
gized.
3.1 Opening and closing doors
Fig. 5-2
3.2 Removing covers
Fig. 5-3
Note
Side walls and the rear wall are connected to the laser device
through a ground cable. When removing or inserting the side
wall and back walls, please pay attention to the grounding cable.
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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
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2018-04 Opening and closing the laser device 5‐9
4. Hose connections
4.1 Connecting the hose
Fig. 5-5
1. Push 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. 5-6
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.
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5. Operating mode
The operating mode TRUMPF maintenance must be active so

that different maintenance activities can be carried out.
5.1 Activating the operating mode

TRUMPF maintenance
Condition
■ User level ≥ 30.
Fig. 5-7
1. Select main activity Maintenance & Commissioning.
20-10-06-A3001-
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2018-04 Operating mode 5‐11
Fig. 5-8
2. Select button Mode.
Fig. 5-9
3. Open selection list.
4. Select TRUMPF maintenance.
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Fig. 5-10
5. Select button Apply.
Fig. 5-11
The maintenance symbol is shown instead of the TRUMPF logo.

The operating mode TRUMPF maintenance is active.
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2018-04 Operating mode 5‐13
6. Laser light cable
6.1 Dismounting and mounting the laser

light cable
A laser light cable must be dismounted and mounted:

■ when you want to transport your laser device.
■ when you want to replace a laser light cable by another with
e.g. another length.
Notes
■ Laser light cables are optical precision parts, which are pro-
duced with maximum accuracy while keeping them extremely
clean. During use of laser light cables, avoid contamination
and mechanical stress (shocks, impacts) of the optical plugs.
■ Only splice LLKs may be installed (see "Fig. 3-23", pg. 3‐22).
Laser light cables must be removed or mounted by instructed

persons only.
Adjustment work is required if a laser light cable with a fiber core
diameter exceeding 100 µm is to be replaced by a laser light
cable with a fiber core diameter of less than 100 µm.
⇒ Please contact the technical service of TRUMPF so that a
service employee can carry out the adjustment work.
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
Working steps
■ Preparations.
■ Disconnect the LLK-D from the laser side.
■ Loosen the LLK-D from the focusing optics.
5‐14 Laser light cable 2018-04 20-10-06-A3001-

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■ Remove and wind up the LLK-D.
■ Final work.
Condition
■ The laser device is switched off and secured against restart.

■ Two protective caps per removed laser light cable.
■ Connectors for each coupling optical unit from which a laser
light cable is removed.
■ Protective caps for the openings at focusing optics from
which the laser light cables are removed.
■ Hexagon screwdriver, 4 mm.
■ Slotted screwdriver, 3 mm.
■ Blow-out device (see "Blow-out device", pg. 5‐6).
Preparations
Fig. 5-12
1. Open hood.
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2018-04 Laser light cable 5‐15
1 Slotted sleeve 3 LLK-D 5 Bolt
2 IFO cable (option) 4 LLK coding cable (option) 6 Holder
Fig. 5-13
2. Remove the support (6) on the bushing from the LLK-D to be
replaced.
3. Remove laser light cable (3) from the slotted sleeve (1).
Now it is possible to disconnect the LLK-D from the laser
side.
Disconnecting the LLK-D 4. Detach monitoring plug.

from the laser side 5. Disconnect the hose coupling of the cooling water hoses.
6. Additionally, remove the following cables if the LLK-D is not
replaced but removed permanently:
− IFO cable (2)
− LLK coding cable(4)
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.

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2. 1.
Fig. 5-14
7. Press the securing ring towards the incoupling optics and
pull out the plug of the LLK-D.
Note
Hold the plug down.
Fig. 5-15
8. Put the protective cap on the LLK-D plug.
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1.
2.
Fig. 5-16
9. Insert the plug into the opening of the incoupling optics.
ILN available Note

The LLK-D and LLK coding cables must always be installed
together in order to avoid mistakes.
The LLK-D and LLK coding cables must be connected by
mechanical means. For this purpose, TRUMPF provides the
cables together with clamps.
1 Clamping piece 2 Screw

Fig. 5-17
10. Unscrew 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
When the focusing optics is mounted on a swiveling support,
for the following activities, the processing optics should be in
a horizontal position if possible. This allows to prevent soiling
of the optical components, which, upon loosening connec-
tions, will be exposed temporarily.

CR02
Fig. 5-18
11. Remove the cooling water hose to the focusing optics.
1.
2. 3.
Fig. 5-19
12. Press down the locking pin, press the slide collar towards
the focusing optics and pull out the plug without tilting or
turning it.
13. Put the protective cap on the LLK-D plug.
14. Insert the plug into opening of focusing optics.
15. Loosen the screw of the clamp (only if ILN is available).
Fig. 5-20
16. Attach protective shells on both plugs of the LLK-D.
The LLK-D is loosened from the focusing optics.
Remove and wind up the 17. Take the LLK-D on the whole length out of the guides, fixing
LLK-D clips, clamps etc.
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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.
18. Wind up the LLK-D to a ring with a diameter of approx. 80
cm.
Removal of the LLK-D is complete.
Dewatering the optical plug Note

of the LLK-D
The quality of the compressed air must correspond to class 3
according to DIN ISO 8573-1 (see "Blow-out device",
pg. 5‐6).
Loss of warranty in case of not dewatered optical plugs of

CAUTION the LLK-D!
If dewatering is not done, the LLK-D may suffer transport
damage: damage to material property.
Ø Dewater the optical plugs of the LLK-D.
19. Connect the blow-out device to a compressed air source.
1 Magnet 2 Blow-out device

Fig. 5-21
20. Attach blow-out device (2) using a magnet (1) to the metal
surface.

CR02
Note
A hose with closure cap, adapter and adapter connections is
included in the accessories of the blow-out device.
Fig. 5-22
21. Connect hose with closure cap (1) to 6 mm/10 mm adapter
(2).
22. Use 10 mm/10 mm adapter connection to connect (3)
adapter (2) and valve (4).
23. Connect hose to valve (4) with blow-out device.
Note
The closure cap (material no.: 1312687) is included in the
accessories of the LLK-D.
Fig. 5-23
24. Fit the closure cap on the sealing nipple of the optical plug.
25. Fit hose with closure cap on the second sealing nipple of the
optical plug.
Note
Cooling water flows out of the open closure cap. An absorb-
ent cleaning cloth can be used to mop it up.
26. Slowly open the valve on the blow-out device and increase
the pressure up to a maximum of 3 bar.
27. If no cooling water flows out any more, close the valve on
the blow-off device.
28. Remove closure cap and hose with closure cap.
20-10-06-A3001-
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Note
Both optical plugs of the LLK-D must be dewatered.
29. Blow out the second optical plug by repeating the procedure.
The optical plugs of the LLK-D are dewatered.
Final work 30. Make sure that protective caps or plugs are mounted on all
openings.
31. Attach the holder of the bushing to the laser device again.
32. Close cover.
Removal of the LLK-D has been completed.
Mounting the LLK-D
Ensure that the cooling of the LLK-D is running for 5 minutes

after switching off the laser.
Working 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.
■ Final work.
Condition

■ Cabinet key
■ Hexagon screwdriver, 4 mm.
■ Slotted screwdriver, 3 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 Plug 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. 5-6

CR02
2. Outside the laser safety cabins, the laser light cables must
be installed permanently and protected.
To do so, use:
− Cable clips
− Cable ducts
− Other appropriate auxiliaries for fastening cables.
3. Laser light cables can be laid freely and loosely inside of
the laser cabins which are monitored by a safety circuit.
To avoid mistakes: 4. If an 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 bend radius must not be
less than 200 mm.
5. Lead the LLK-D and LLK coding cables (if available) and the
cooling water hoses by means of guides or fixing clips
towards the processing point.
Preparing the laser device
Fig. 5-24
6. Open hood.
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1 Holder
Fig. 5-25
7. Remove the required holder (1) from the bushing.
Connecting the LLK-D to the

laser device
1 Protective shell 3 Protection foil

2 Seal
Fig. 5-26
8. Remove the protective shell from the optical plug, break the
seal and remove the protective film.
Notes
■ Make sure that no dirt falls into the openings with
removed protective caps.
■ Hold the plug down.

CR02
Fig. 5-27
9. Pull the protective cap from the incoupling connector.
1.
2.
Fig. 5-28
10. Remove the plug from the opening of the incoupling optics.
Note
It is absolutely necessary that the optical plug is inserted in
the incoupling optics to the stop.
20-10-06-A3001-
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2. 1.
Fig. 5-29
11. Press the securing ring towards the incoupling optics and
keep it pressed during the insertion process. Insert the opti-
cal plug into the incoupling optics to the stop.
Connecting hoses and 12. Connect the monitoring plug.

connectors
Note
Do not tilt the cooling water hoses when connecting them.
13. Connect the cooling water hoses:
The LLK-D is connected to the incoupling optics and the
monitoring electronics.
Fit the protective cap and the plug together and store them
in a safe place.

CR02
Closing the LLK bushing at
the laser device
1 Slotted sleeve 3 LLK-D 5 Bolt

2 IFO cable (option) 4 LLK coding cable (option) 6 Holder
Fig. 5-30
14. Insert the LLK-D and, if available, other cables in the slotted
sleeves (1).
15. Fasten the holder (6) using bolt (5).
16. Close cover.
ILN available Note

The LLK-D and LLK coding cables must always be installed
together in order to avoid mistakes.
The LLK-D and LLK coding cables must be connected by
mechanical means. For this purpose, TRUMPF provides the
cables together with clamps.
20-10-06-A3001-
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1 Clamping piece 2 Screw
Fig. 5-31
17. Connect the LLK-D to the respective LLK coding cable using
clamp (1) and tighten screw (2) (see Interface description
"Interface LaserNetwork (ILN)").
Connecting the LLK-D to the Note

focusing optics
When the focusing optics is mounted on a swiveling support,
for the following activities, the processing optics should be in
a horizontal position if possible. This allows to prevent soiling
of the optical components, which, upon loosening connec-
tions, will be exposed temporarily.
Fig. 5-32
the focusing optics and remove the protective cap of the
focusing optics.
19. Remove the protective shell from the optical plug, break the
seal and remove the protective film.

CR02
Notes
■ Make sure that no dirt falls into the openings with
removed protective caps.
20. Remove the protective cap from the optical plug.
Fig. 5-33
21. 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.
23. Check whether the optical plug engages correctly into the
focusing optics and cannot be pulled out.
24. Check whether the slide collar has close contact with the
optical plug in order to avoid the penetration of dirt.
ILN available 25. 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 cabin.
More information can be found in the Test procedure “Inter-
face LaserNetwork LLK coding cable”, which is enclosed with
each LLK coding cable.
26. Check connection (see Interface description "Interface Laser-
Network (ILN)").
20-10-06-A3001-
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Connecting the cooling
water hoses
1 Supply hose 2 Return hose

Fig. 5-34
27. Connect the supply hose (1) to the focusing optics.

28. Connect the return hose (2) to the plug.
The LLK-D has been connected to the focusing optics.
Final work 29. If there is no ILN, switch the laser device and control unit on.
30. Check newly established cooling water connections for leaks:
− On the incoupling optics at the laser device.
− at the focusing optics.
31. Close the right front door.
The LLK-D and the respective LLK coding cable, in case that
ILN is available, have been installed.
6.2 Maintaining laser light cable
Replacing the protective sleeve with

protective glass at the LLK-D
Reason:
Too much scattered light in the incoupling optics.

■ Protective sleeve with protective glass for LLK-D (material
no. 1342948).
■ Torque screwdriver 2 Nm (material no.1326948).
■ Bit-holder, universal 1/4" 162 mm (material no. 2019453).
■ Torque inserts for protective sleeve (material no. 1359017).
■ LED, Lenser (material no. 1632115).
■ Measuring magnifier for checking the protective glass, LLK-D
(material no. 1995032).

CR02
Notes
■ Never touch the light guide (2).
■ Ensure that the light guide is neither soiled nor damaged.
■ With the protective 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 protective glass of the new protective
sleeve.
■ Make sure that no dirt particles enter the new protective
sleeve.
1 Optical plug of the LLK-D 3 Protective sleeve with protective 5 Mounting key
2 Light guide glass 6 Notch
4 Protecting cap
Replacing the protective sleeve along with the protective glass Fig. 5-35
Checking protective glass Note

for contamination
The focal position can be adjusted by turning the measuring
magnifier.
20-10-06-A3001-
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Fig. 5-36
1. Check the protective glass for contamination with a measur-
ing magnifier and LED Lenser.
If there are particles or scorching on the protective glass, it
will need to be replaced.
Removing defective Note

protective sleeve along with
If you remove the protective sleeve laterally, there is a risk
protective glass
that the light guide becomes damaged.
Fig. 5-37
2. Remove the protective sleeve cautiously in beam direction
from the optical plug.

CR02
Mounting a new protective
sleeve along with the
protective glass
Fig. 5-38
3. Remove the protective cap from the packaging of the protec-
tive sleeve with protective glass.
Fig. 5-39
4. Fasten new protective sleeve with the assembly wrench.
Fig. 5-40
5. Tighten new protective sleeve with torque screwdriver
(2 Nm).
6. Dispose of the removed protective sleeve as household
waste.
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7. Diode power supply (DPS)
The following figure shows the position of the diode power sup-
ply (DPS) in the laser device, which can be replaced.
Fig. 5-41
Note
A defective DPS can only be repaired and checked by TRUMPF
Laser and then be released for further use.
5‐34 Diode power supply (DPS) 2018-04 20-10-06-A3001-

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7.1 Replacing the diode power supply
(DPS)
Condition

■ Cabinet key
■ Cross-tip screwdriver, PH1, PZ2.
■ Torx screwdriver, T25.
■ Slotted screwdriver, 2.5 mm.
■ Drip pan and cleaning cloth for cooling water.
Removing the diode power 1. Open the left front door of the laser device.
supply (DPS)
Dangerous electrical voltage in the mains distribution!

DANGER
Touching live electric parts can be life-threatening.
Ø Only qualified electricians may work on the mains distribu-
tion.
Ø The mains plug of the laser device must be disconnected
and secured against unauthorized connection.
Ø Before touching live electric parts, always check for absence
of power.
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2018-04 Diode power supply (DPS) 5‐35
1 Fastening screws (2x) 5 Drip pan
2 Connector, current output 6 Connector, mains connection
(4x) 7 Connector, CAN bus
3 Connector, control voltage
4 Cooling water connection (2x)
Fig. 5-42
2. Remove connectors (2, 3, 6 and 7).
− Remember the position of the CAN bus connector (7).
3. Unscrew the fastening screws with washers (1).
Note
Make sure that no cables or hoses under the diode power
supply become damaged when removing the diode power
supply.
4. Pull the DPS approx. 5 cm out of the guide so that the cool-
ing water connections (4) protrude over the edge of the
device.
5. Place the collecting basin (5) under the cooling water con-
nections (4).
6. Open the hood.

CR02
Fig. 5-43
7. Pull the plug B23/C23 off of the water distributor.
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 glasses and protective cloth-
ing.
8. Pull both cooling water connections (4) off of the quick-acting

couplings simultaneously.
DI water drains out of the cooling water connections of the
DPS.
9. Reinsert the removed plugs in the water distributor B23/C23.
10. Collect the draining cooling water with a cloth.
11. Close cover.
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.
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12. Hold the DPS and completely pull out of the device on the
guide rail and put it down on a solid surface.
Installing the diode power 13. Mount the new diode power supply in reverse order and dur-
supply (DPS) ing this operation:
− do not damage hoses and cables.
− Do not mix up the CAN bus connectors (7).
1 Rotary switch for CAN bus address

Fig. 5-44
14. Set the rotary switch situated on the DPS on the value of the
removed DPS.

CR02
Replacing the mains
contactor Q1
1 Fastening screws (2x) 2 Cover plate

Fig. 5-45
15. Loosen both fastening screws (1).
16. Push the cover sheet (2) upward and remove.
Note
Pay attention to connected cables!
17. Tilt the cover plate (2) forwards.
1 Clamping screws (6x) for 3 Stranded wires for control volt- 4 Clamping screw for control volt-
switching voltage connections age age (2x)
2 Stranded wires for switching
voltage (400 V)
Fig. 5-46
18. Loosen the clamping screws (1) of the connections for the
switching voltage and pull out the connection wires (6x).
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19. Loosen the clamping screws (4) of the connections for the
control voltage and pull out the connection wires (2x).
20. Press the mains contactor (Q1) downward and pull outward.
21. Remove line contactor from the top-hat rail.
22. Take the marking label from the removed mains contactor
and apply it to the new mains contactor.
Note
When connecting the stranded wires for the switching volt-
age, pay attention to the markings.
When connecting the stranded wires for the control voltage,
pay attention to the markings and a tight fit at the connection
point.
23. Mount the new mains contactor in reverse order and connect
it.
The mains contactor (Q1) is replaced.
Transmission of the setting 24. Switch on laser device and control.

data from the CPX to the
A fault due to modified control configuration is displayed.
DPS
25. Select the >Setup >Plug & Play overview dialog.
Fig. 5-47
26. Select the line with the symbol for modified configuration (5).
27. Press the Synchron. configurat. button (6).
28. Select Use saved setting data for the replaced component
(7).

CR02
29. Press the Next button (8).
The CPX transmits the safe configuration data to the DPS.
This completes the replacement of the diode power supply
(DPS).
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8. Laser cooler
The following maintenance work on the laser cooler might be

necessary:
■ Fill the cooling unit.
■ Drain off the cooling unit.
■ Cleaning the contamination filter.
■ Replacing filter element in the fine filter.
■ Cleaning the laser circuit.
− Cleaning the tank.
■ Refill the cooling water.
1 Tank 3 Contamination filter

2 Fine filter
Fig. 5-48
In order to avoid deposits and soiling of the laser circuit, observe

the following
■ Regurlarily check the quality of the cooling water.
■ Keep the doors and the hood closed.
■ Keep the tank's cover closed.
■ If deposits and contamination occur in the laser circuit, clean
the cooling circuit and replace the filter element in the micro-
filter.
■ Observe the maintenance intervals.
■ Before connecting new components (e.g. focusing optics
PFO), purge them with deionized water (6 - 10 μS/cm).
■ New components must be free of oil and grease.
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8.1 Filling the cooling unit
Conditions
■ The laser device is connected to the mains.
■ External cooling water lines are connected.
■ Operating mode TRUMPF maintenance is active (see "Acti-
vating the operating mode TRUMPF maintenance", pg. 5‐11).
■ Key-operated switch is in position Laser locked.

■ Deionized water (DI water prepared from water in drinking
water grade), 55 l.
■ Cooling water additive Water Care-Copper (corrosion protec-
tion), Material-No.: (see "Cooling water additives", pg. 5‐4).
■ Gloves, safety glasses
■
■
■ , protective clothing to protect you against deionized water
and cooling water additives.
■ Cabinet key
■ Cleaning cloth for wiping up of spilled cooling water.
Preparations 1. Remove the rear wall of the laser device.

2. Open the hood.
Check connections Note

To empty the laser device, connections have been discon-
nected. This is why all connections that were disconnected
must be checked before filling the cooling unit.
20-10-06-A3001-
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1 Fine filter 4 Drain hose / level indicator
2 3 BW-VL for tank
3 Drain hose for pump 5 4 BW-RL
6 Contamination filter
Fig. 5-49
3. Check whether the connections are complete and connected
or closed correctly.
4. Check whether all plugs are inserted.
Fig. 5-50
5. Check if plugs B23 and C23 (2x) are present.
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Filling the laser circuit
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.
6. Unlock the sash lock on the cover of the tank with a cabinet
key and remove the cover.
Fig. 5-51
7. Top up with DI water until the water level reaches the 100 %
mark.
8. Switch on the laser device.
9. Turn the key-operated switch to Laser locked position.
10. Switch on control unit.
Checking for leaks
Fig. 5-52
20-10-06-A3001-
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11. Briefly press the pump push-button several times, then for a
longer period.
Deionized water flows through the components of the laser
circuit.
12. Check the connections for tightness.
13. Seal the leak points if there are any.
14. Wipe off drained cooling water with a clean cloth.
Topping up DI water Note

Filling the components to be cooled caused the water level
in the tank to drop. If the water level has fallen below the
100 % mark, deionized water has to be topped up.
mark.
Filling in anticorrosive
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".
5‐46 Laser cooler 2018-04 20-10-06-A3001-

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Fig. 5-53
16. Fill the complete bottle of anticorrosive agent (yellow lid) in
the tank.
17. Close the tank cover.
19. Let the cooling unit run for 1 min.
Filling the external circuit
Fig. 5-54
21. Open the building's water connections and shut-off valves
first in the supply line and the return line of the external cir-
cuit.
Water flows into the external circuit.
20-10-06-A3001-
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Fig. 5-55
22. Check the contamination filter for leaks.
23. Fit cover on the right side
24. Attach the rear panel.
25. Close the cover.
The internal and external circuits are full.
The laser device is ready for use.
8.2 Emptying the cooling unit
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.
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Conditions
■ The laser device is switched on.

■ Cabinet key
■ Open-end wrench, 34 mm
■ Disposal gloves, gloves, safety glasses, protective clothing to
protect you against DI water and cooling water additives.
■ Collecting pan with a capacity of about 60 l.
■ Flat pan with a capacity of about 10 liters.
■ Blow-out device (contains hose bridges and blow-out
adapter), (see "Blow-out device", pg. 5‐6).
■ Compressed air source with a volumetric flow rate of
500 Nl/min and a pressure of 2 bar to a maximum of 6 bar
on the blow-out adapter. The quality of the compressed air
must correspond to class 3 according to DIN ISO 8573-1.
Note
The user must match the disposal of the cooling water with the
responsible local disposal authority.
The cooling water from the external cooling circuit can be dis-
posed of in the sewerage system provided that it does not con-
tain any additives (e.g. anti-freeze or biocides).
Preparations 1. Remove the rear wall of the laser device.

2. Remove cover on the right side.
Emptying the external circuit 3. Switch on control.
20-10-06-A3001-
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Fig. 5-56
4. Select Enable emptying in the >Maintenance & Commission-
ing >Empty cooling circuit dialog.
The display (arrow) must shine green.
5. First connect the supply and then the return of the domestic
water connections to the external circuit. The stop valves of
the cooling water connections remain open.
1 Return ball cock 2 Supply ball cock

Fig. 5-57
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6. Check if the supply ball cock (1) and the return ball cock (2)
are open.
Fig. 5-58
7. Place a flat pan (10 liters) on the floor in front of the laser
device.
1 3 BW-VL 3 Velcro fastener

2 Stop valve 4 4 BW-RL
Fig. 5-59
8. Open the Velcro fasteners (3).
9. Place the hose 3 BW-VL (1) in the pan and pull out the plug.
10. Slowly open the shut-off valve (2) on hose 3 BW-VL (1).
11. Place the hose 4 BW-RL (4) in the pan and pull out the plug.
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12. Slowly open the shut-off valve (2) on hose 4 BW-RL (4).
Fig. 5-60
13. If no cooling water escapes any more:
place a flat pan (10 liters) on the floor in front of the laser
device.
Fig. 5-61
14. Disconnect the cooling water hoses.
The remaining cooling water drains out of the cooling water
connections.
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1 Return ball cock
Fig. 5-62
15. Close the return line ball cock (1).

Fig. 5-63
surface.
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1 Valve, blow-out device 3 Shut-off valve 4 BW-RL
2 Adapter 10 mm 4 4 BW-RL
Fig. 5-64
17. Fit an adapter 10 mm (2) in the shut-off valve (3) of hose 4
BW-RL (4).
18. Fit valve of blow-out device (1) on adapter, 10 mm (2).
19. Open shut-off valve (3).
Note
The pressure must be at least 2 bar and must not exceed 6
bar.
20. Open valve of blow-out device (1).
The external cooling circuit is blown out.
21. If no more cooling water escapes:
− Remove blow-out device.
− Close the stopcocks.
− Insert plugs in 3 BW-VL and 4 BW-RL.
− Attach 3 BW-VL and 4 BW-RL to cooling unit using Vel-
cro fasteners.
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Fig. 5-65
22. Clean the contamination filter (see "Cleaning the contamina-
tion filter", pg. 5‐67).
23. Switch off the control.
The external cooling circuit has been drained.
24. Seal fittings on the cooling water connections with protective
plugs or adhesive tape.
Emptying the laser circuit

CAUTION water!
ing.
ing.
20-10-06-A3001-
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Fig. 5-66
25. Place a pan (60 liters) on the floor in front of the laser
device.
1 Drain hose/level display for 2 Drain hose, pump

tank
Fig. 5-67
26. Remove sealing cap from hose (1) and carefully place it in
the pan.
27. Remove sealing cap from hose (2) and carefully place it in
the pan.
28. Open the hood.
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Fig. 5-68
29. Remove plugs B23 and C23 from the cooling water distribu-
tor (2x).
Air gets into the laser circuit. The treated DI-water in the opti-
cal compartment runs into the tank of the laser cooler.
Note
Leave the hoses in the pan.
Fig. 5-69
30. Refit plugs B23 and C23 on the cooling water distributor.
Note
The next step is only necessary if no laser light cable is con-
nected.
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1 Hose bridge
Fig. 5-70
31. Connect hose bridge (1) to laser light cable cooling connec-
tion.

Fig. 5-71
surface.
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Fig. 5-72
33. Connect valve of blow-out device with 10 mm adapter to
supply line pump modules.
Note
bar.
34. Blow out until no water emerges any more.
Note
The next step is only necessary if no further laser light cable
is connected.
35. Attach hose bridge to other laser light cable cooling connec-
tion.
Note
bar.
37. Release the compressed air connection and close the open
point on the water distributor.
20-10-06-A3001-
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Fig. 5-73
38. Release hose at slot B13.

Fig. 5-74
surface.
40. Fit the 10 mm adapter on the valve of the blow-out device.
41. Fit the 10 mm to 6 mm coupling on the 10 mm adapter.
42. Insert supply hose in the 10 mm to 6 mm coupling.
Note
bar.
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44. Repeat procedure up to supply hose B21.
At supply hose B21, the 10 mm to 6 mm coupling must be
replaced with a 10 mm to 8 mm coupling.
Fig. 5-75
45. Remove return hose C2 and place it in the pan.
Fig. 5-76
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46. Remove supply hose B2 for cabinet heat exchanger / DPS
from water distributor.

Fig. 5-77
surface.
48. Connect blow-out device with 10 mm to 8 mm coupling to
supply hose B2.
49. Slowly open the blow-out device valve.
Note
bar.
51. Reconnect supply hose B2 and return hose C2 to the water
distributor
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Fig. 5-78
52. Disconnect the return hose lever arm connection.
53. Put hose into the collecting pan.
The remaining cooling water flows out of the return hose.
Wait until no more cooling water flows out.
Fig. 5-79
54. Connect the return hose lever arm connection again and
secure it with cable ties.
55. Open the Velcro fasteners on the filter element.
56. Loosen filter cup with the filter spanner.
Note
Only touch the filter element when wearing clean gloves!
20-10-06-A3001-
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Fig. 5-80
57. Take off the filter cup.
58. Remove the filter element and pour the cooling water from
the filter cup into the collecting pan.
If the filter element is severely soiled, replace the filter ele-
ment (see "Replacing filter element in the fine filter",
pg. 5‐71).
59. Wipe off leaked cooling water with a clean cloth.
60. Introduce the filter element carefully into the filter cup.
61. Check if the sealing ring is inserted correctly in the filter cup.
62. Reattach the filter cup.
The microfilter is empty.
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Draining option BEO water
distributor
Fig. 5-81
63. Remove plug from underneath.
Mop up the water that escapes with an appropriate cloth
64. If no cooling water escapes any more, the plugs can be re-
inserted.
Draining the optional

cooling water interface of
the laser machine
Fig. 5-82
65. Place a pan under the cooling water connections.
20-10-06-A3001-
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Fig. 5-83
66. Open the ball cock on the supply and return hose.
67. If no cooling water escapes any more, fit cover caps on the
cooling water connections.
Draining pressure-free return

option
Fig. 5-84
68. Place a pan under the cooling water connections.
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Fig. 5-85
69. Remove the plug.
70. If no cooling water escapes any more, refit the plugs.
Final work 71. Replace the plug.

72. Remove the hose bridge.
73. Re-attach the hoses to the fasteners.
74. Close the cover.
75. Attach the rear wall of the laser device.
76. Attach the cover on the right side wall.
77. The user must match 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 addi-
tives (e.g. anti-freeze or biocides).
This completes the emptying of the laser device.
8.3 Cleaning the contamination filter
Condition

■ Cabinet key
■ Fork wrench, 34 mm
■ Cleaning brushes
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■ If required:
Set of wearing parts for contamination filter, Material
No.: (see "Material", pg. 5‐4).
1. Remove the rear wall of the laser device.
Fig. 5-86
2. Shut the stop valves of the external circuit.
Fig. 5-87
3. Put collecting pan on the floor in front of the laser device.
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1 3 BW-VL 3 Velcro fastener
2 Stop valve 4 4 BW-RL
Fig. 5-88
4. Open the velcro fastener (3).
5. Place the hose 3 BW-VL (1) in the pan and pull out the plug.
6. Slowly open the shut-off valve (2) on hose 3 BW-VL (1).
Cooling water drains off and the pressure in the external cir-
cuit is reduced.
7. Place the hose 4 BW-RL (4) in the pan and pull out the plug.
8. Slowly open the shut-off valve (2) on hose 4 BW-RL (4).
Fig. 5-89
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9. Carefully release the contamination filter using a 34 mm
open-end wrench.
Fig. 5-90
10. Clean the outside of the filter insert under running water
using a soft brush.
11. Check the sealing ring of the filter insert and replace it, if
necessary.
12. Screw in and tighten the filter element again.
13. Close shut-off valve (2) on hose 3 BW-VL (1).
14. Close shut-off valve (2) on hose 4 BW-RL (4).
15. Re-insert plugs in hoses 3 BW-VL and 4 BW-RL.
Fig. 5-91
16. Open shut-off valves first in the supply line and in the return
line of the external circuit.
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17. Check the contamination filter for leaks. If it leaks, retighten
the screws of the filter insert or, if necessary, replace the
sealing ring.
8.4 Replacing filter element in the fine

filter
The filter element in the microfilter 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.
Conditions
■ Turn the key-operated switch to Laser locked position.

■ Gloves for protection against cooling water.
■ Disposal gloves for protection of the filter element
■ Absorbent cloth.
■ Collecting pan with about 5 l capacity.
■ Filter element, Material No.: (see "Tab. 5-1", pg. 5‐4).
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.
Preparation 1. Remove the rear wall of the laser device.

2. Open the Velcro fasteners on the filter element.
20-10-06-A3001-
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CAUTION
ing.

Replacing the filter element Note

There is still cooling water in the filter cup.
Fig. 5-92
5. Remove the filter cup together with the filter element.
6. Carefully take the filter element out of the filter cup and allow
it to dry in an appropriate vessel.
7. Pour the cooling water being in the filter cup into the collect-
ing pan.
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Fig. 5-93
8. Put on disposal gloves to protect the new filter element
against contamination (grease, germs).
9. Open the protective film of the new filter element and insert
the new filter element.
10. Reassemble the microfilter in the reverse order.
Checking for leaks
Fig. 5-94
longer period.
12. Check the microfilter for tightness.
If the microfilter is leaky, check fit and state of the O-ring.
Replace O-ring in case of damage or wear.
Final work 13. Check the deionized water level in the tank. Top up with
deionized water until the 100 % mark is reached (see "Refill
the cooling water", pg. 5‐87).
8.5 Cleaning the laser 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 Maintenance & Commissioning dialog
box indicate that the laser circuit has to be cleaned.
20-10-06-A3001-
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Fig. 5-95
The change of water must be acknowledged in the Maintenance

& Commissioning dialog box. 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, TRUMPF has only released
the cooling water additives specified in the table (see "Tab. 5-7",
pg. 5‐75). 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.
■ Protective gloves
■ 2 bottles of cooling water additives.
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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. 5-7
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. 5‐4).
Note
Due to the limited shelf life (see “Expiration date” indicated on
the bottles), it is recommended to adapt the ordered quantity to
your present needs.
Apportionment Metering is performed by means of bottles, so that the required

quantity does not have to be measured.
Disposal of the cooling The user must match the disposal of the cooling water with the
water responsible local disposal authority.
Carrying out cleaning cycle and cooling

water replacement
In the following section, the cleaning cycle and the cooling water
replacement is described.
The following steps are necessary:

■ Preparations
■ Carry out the cleaning cycle.
■ Empty the optical compartment.
■ Emptying the microfilter.
■ Emptying the tank, Cleaning the tank.
■ Emptying the pump.
■ Filling the tank.
■ Checking the tightness of cooling unit.
■ Check the conductivity of the cooling water, rinse the system,
if necessary.
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■ Acknowledge the cleaning cycle in TruControl 1000.
■ Note on the label of the tank that the cleaning procedure has
been carried out.
Condition

■ Cabinet key
water grade), 55 l.
■ Disposal gloves, gloves, safety glasses, protective clothing to
protect you against DI water and cooling water additives.
■ Cooling water additives, material no.:(see "Tab. 5-7",
pg. 5‐75).
■ If necessary, filter element in the tank, material no.:(see "Tab.
5-1", pg. 5‐4).
■ Water-resistant pencil to note the cleaning procedure on the
label of the tank.

CAUTION water!
ing.
ing.
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textiles!
and textiles.
mouth.
ing.
"Easy-Kit".
Preparations 1. Put on protective gloves, safety glasses and protective cloth-

ing.
3. Remove the rear wall of the laser device.
Fig. 5-96
5. Put the tray on the floor in front of the laser device.
7. Check the tank for dirt and deposits.
8. If there visible deposits and signs of soiling:
Carry out the the steps 16 to 42 before filling in the cleaning
biocide.
20-10-06-A3001-
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Note
The conductivity monitoring may interfere with the operation
during the cleaning procedure.
44
BR-52095en
Fig. 5-97
9. Press the Monitoring conduct. off button.
The laser can be operated during the cleaning procedure.
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Fig. 5-98
10. Fill the complete bottle of cleaning biocide (red cap) com-
pletely in the tank.
12. Switch on control unit.
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Carry out the cleaning cycle
BR-52072en
Fig. 5-99
14. Allow the cooling unit to run for 1 h. In the >Maintenance &
Commissioning dialog, check whether the cooling unit is on:
− The display (arrow) must shine green.
The cooling water with the cleaning biocide circulates
through the laser circuit. Any germs that are present will be
killed.
The cleaning cycle is carried out.
Emptying the optical

compartment
Fig. 5-100
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16. Remove plugs B23 and C23 from the cooling water distribu-
tor (2x).
Air gets into the cooling circuit. The cooling water from the
optical compartment flows into the tank of the laser cooling
unit.
18. Reattach the plug.
The optical compartment is empty.
Emptying the microfilter 19. Open the Velcro fasteners on the filter element.
Note
Only touch the filter element when wearing clean gloves!
Fig. 5-101
21. Take off the filter cup.
22. Remove the filter element and pour the cooling water from
the filter cup into the collecting pan.
24. Check the filter cup for dirt.
25. If necessary, clean the filter cup under running tap water
(drinking water quality).
26. Introduce the filter element carefully into the filter cup.
27. Reattach the filter cup.
The microfilter is empty.
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Emptying the tank
1 Drain hose/level display for tank

Fig. 5-102
28. Place the drain hose / level indicator of tank (1) in the pan
and remove the sealing cap.
29. Remove the cooling water completely from the tank.
31. Dispose of the cooling water according to the disposal regu-
lations.
32. Wear disposable gloves.
33. Clean the inside of the tank (walls and bottom) using deion-
ized water and a clean cloth.
Do not use cleaning additives.
Fig. 5-103
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34. Remove the filter of the tank and check if it is soiled.
35. If necessary, clean the filter under running tap water (drinking
water quality) using a fluff-free cloth.
If the filter is damaged, replace it, (see "Tab. 5-1", pg. 5‐4).
36. Install the filter.
37. Attach the sealing cap to hose no. 1.
The tank is empty.
Emptying the pump
2 Drain hose for pump

Fig. 5-104
38. Place drain hose of pump (2) in the pan and remove the
sealing cap.
The cooling water flows out of the pump.
40. If no more cooling water runs out of the pump: re-attach
plug.
The pump is empty.
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Filling the tank
Fig. 5-105
mark.
43. Close the tank cover
The tank is full.
Checking the tightness of

cooling unit
Fig. 5-106
longer period.
45. Check distributor, drain hoses and fine filter for leaks.
46. Seal the leak points if there are any
47. Wipe off drained cooling water with a clean cloth.
49. Check in >Maintenance & Commissioning >Cleaning laser
circuit check whether the pump is really switched on.
50. Let the cooling unit run for 10 minutes.
Cooling water flows into the microfilter, through the pump
units and the connected focusing optics. The laser circuit is
flushed.
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Check the conductivity of
the cooling water
BR-52075en
Fig. 5-107
51. Check conductivity: >Maintenance & Commissioning >Clean
laser circuit.
52. If the conductivity value of the cooling water is
≥ 20 μS/cm after rinsing:
Repeat the steps beginning with “Emptying optical compart-
ment” until the conductivity after rinsing has reached the
value between 6 and 20 μS/cm.
or
Ø If the conductivity value of the cooling water is
between 6 and 20 μS/cm after rinsing:
If necessary, top up with DI water until the water level
reaches the 100 % mark (see "Refill the cooling water",
pg. 5‐87).
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textiles!
and textiles.
mouth.
ing.
"Easy-Kit".
Fig. 5-108
55. Completely fill the copper anticorrosive agent (yellow lid) into
the tank.
Acknowledging the change 58. Using a water-proof marker, note down the cleaning on the
of water and noting it label of the tank.
59. Attach the covers to the laser device.
60. Acknowledge cleaning in TruControl 1000: >Maintenance &
Commissioning >Clean cooling circuit.
The maintenance work is finished.
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8.6 Refill the cooling water
Cooling water must be topped up if:

■ a message is indicated on the monitor stating that the water
level in the tank is too low.
■ The tank level has dropped below the minimum mark.
Conditions

■ Cabinet key.
■ Water can.
water grade).
Conductivity 6 - 10 µS/cm
■ Wear Gloves for protection against DI water, protective cloth-
ing and safety goggles.
Note
If a large amount of cooling water (more than half the tank vol-
ume) must be poured in the tank, an anticorrosive agent must
be added (see "Cooling water additives", pg. 5‐4).
1. Remove rear side of the laser device.

CAUTION
ing.
20-10-06-A3001-
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Fig. 5-109
mark.
Fig. 5-110
4. Press the pump button for approx. 1 min.
5. Check the water level and fill in cooling water up to the
100 % mark.
The laser device is ready for use
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8.7 Checking the tightness of cooling
unit
Conditions
■ The laser device has been switched on.
■ The external cooling circuit is connected and supplied with
the working pressure of the cooling water.

■ Cabinet key
1. Remove rear side of the laser device.

4. Switch on control.
Fig. 5-111
5. Select TruControl 1000 Maintenance & Commissioning.
6. Select pump button.
7. Press the pump button for 5 seconds.
The pump pumps cooling water through the cooling circuit.
8. Observe all the components, hoses and tubes of the laser
circuit while the pump is working.
9. 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.
− Insert the O-rings, e.g. into the filter cup of the microfilter.
20-10-06-A3001-
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− Loosen the quick-release couplings, re-attach or replace
them.
− Fasten the sealing clamps.
− Fasten the union nuts.
10. If a part that contains or supplies water is damaged:
Informing the TRUMPF service department.
13. Mount the cover on the right side.
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9. Electrics
Maintenance work on the electrics is limited to changing fuses

and switching on power circuit breakers when they are triggered
due to a malfunction.
A blown fuse has to be changed. A power circuit breaker that
has tripped must be switched on again. This is indicated by the
failure of partial functions or through corresponding messages on
the monitor.
9.1 Identifying blown electrical fuses
Conditions
■ The laser device is connected to the mains.
■ The main switch is in ON position.
■ The control unit of the laser device is on.

■ Cabinet key
Dangerous electric voltage inside the laser device!

DANGER
gized.
Preparation 1. Open the left front door.
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2018-04 Electrics 5‐91
The mains distributor is accessible.
1 Circuit breaker 2 Microfuses

Fig. 5-112
Determine the triggered

microfuse
Fig. 5-113
2. Check the LEDs on the PSB board.
LED for Function

fuse
F1 Dehumidifier, RDS 1/2
F2 Laser control system/central processor
F3 Inverter of service socket
F4 Cooling control board, CCB
F5 Cabinet fan
F6 Clean air inflator, CAI (option)
F7 Power supply, DPS 1/2
F8 Laser power supply, DPS 3/4
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LED for Function
fuse
F9 Mains distribution control board, CMD
F10 CPX_Standby
F11 PFO option
F12 Air conditioning fan
F13 User's compartment
F14 Peltier element, tropical option
Tab. 5-8
With control voltage applied (from power supply) and intact

fuse, the LED will be lit.
3. Switching off the laser device.
9.2 Replacing the microfuse
Conditions
■ The triggered microfuse must have been determined (see
"Identifying blown electrical fuses ", pg. 5‐91).
Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø The laser must be switched off when fuses are changed.
1. Pull out the triggered fuse.

2. Eliminate the cause of the microfuse triggering. Otherwise,
the replaced microfuse may be triggered 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 triggered microfuse by a new intact microfuse of the
same type.
4. Switch on the laser device.
5. Check LEDs.
6. If other LEDs do not light up, also check the corresponding
microfuses, and replace them if necessary.
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2018-04 Electrics 5‐93
7. Close the left front door.
9.3 Activating the power circuit breaker
Condition
Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Circuit breakers may be switched on only while the device is
turned off.
Fig. 5-114
1. Eliminate the cause that made the power circuit breaker trip.
Otherwise, the power circuit breaker might trip again as soon
as the device is switched on.
2. Turn the black switch of the tripped power circuit breaker
upwards.
3. Close the left front door.
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Chapter 6
What to do 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 Malfunction 6‐5
4 Dealing with messages 6‐7

4.1 Message structure 6‐7
4.2 History of messages 6‐9
Displaying the history of messages 6‐9
Setting the message filter 6‐9
Searching for a message 6‐10
Type of message 6‐12
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2018-04 What to do 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 that can carry dangerous voltages dur-
ing operation, check that they are free of voltage.
Ø Wear personal safety 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.
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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.
20-10-06-A3001-
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2018-04 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 control signals are checked for plausibility.
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 “Monitoring” sign 3 Message code

2 Reporting subassembly 4 Short message text
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 2018-04 20-10-06-A3001-

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"Monitoring" sign The symbol indicates a monitoring message in the tool bar.
There is another symbol which belongs to the category of moni-
toring messages:
Symbol Category Explanation

Light path monitoring Processing can continue.
Tab. 6-1
Message code Via the display of the message memory it is possible to call up
the message text:
⇒ Select the main activity Diagnostics.
The message stack is displayed.
Short message text The short text gives the operator one-line information on the
cause for the message.
Note
If a monitoring message is displayed, operation of the laser
device is still possible. However, the cause for the message
should be eliminated at the first opportunity. If the cause is not
eliminated, a monitored operating value may exceed the fault
limit soon (see section Fault).
In case of malfunction, the laser device cannot be operated until
the cause of the malfunction has been eliminated.
3.2 Malfunction
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 switched off automatically.
■ a fault message is displayed on the screen.
Fault message The red display "Fault" is illuminated in the main dialog of Tru-
Control 1000.
20-10-06-A3001-
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2018-04 Monitoring and faults 6‐5
Fig. 6-3
1 “Fault” sign 3 Message code

2 Reporting subassembly 4 Short message text
A fault message is displayed Fig. 6-4
There is another symbol which belongs to the category of fault

messages:

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, refer to
chapter "Operation", section "How to respond to messages".
6‐6 Monitoring and faults 2018-04 20-10-06-A3001-

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4. Dealing with messages
4.1 Message structure
In order to display a text message:
Displaying a message text 1. Select the Diagnostics main operation.

2. Call messages using .
Active, not yet processed messages are displayed.
Displaying a message text Fig. 6-5

3. Mark the message (1).
4. Select Dispay (2).
The following display appears on the monitor:
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2018-04 Dealing with messages 6‐7
1 Date, time of day, message 3 Message text 5 Scroll bar
code, board 4 Number of causes 6 Context bar
2 Short message text
Fig. 6-6
Display
Date and time when the message occurred is displayed (1).
Additionally, the message code and the name of the board
that has created the message are displayed.
Short text
The short text (2) is the same as in the main dialog of Tru-
Control 1000.
Text message
The text message (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 Next cause button, 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 possible causes for a message (4).
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4.2 History of messages
All messages are entered in a message history so that they can

still be read even after resetting the laser device. This function is
helpful for diagnostic purposes.
Displaying the history of messages
1. Select the Diagnostics main operation.

Fig. 6-7
3. Call message history using the Show history button.
The history of messages is displayed.
Setting the message filter

Active messages are displayed.
3. Select Change filter.
The filter settings are displayed.
20-10-06-A3001-
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Message filter Fig. 6-8
4. Tick the check boxes for the message types to be displayed
in the message list.
5. Select Apply.
The filter settings are displayed.
Searching for a message
There are Expert dialogs in all secondary operations of the main

operation Diagnostics. Expert dialogs contain extended dialogs
for diagnostics purposes for the TRUMPF service or for trained
users of the laser devices.
In extended diagnostics 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 Expert dialogs button.

Expert dialog button Fig. 6-9

CR02
3. Select Expert dialog.
The Search message text dialog box is opened.
4. Enter the message code and select Search.
The message is displayed.
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Type of message
The categories are marked with symbols.

Malfunction The laser is switched off.
The message must be acknowledged
with Reset.
Monitoring Processing can continue.
The message must be acknowledged
with Reset.
Light path fault Light path is blocked.
Must be acknowledged by means of
Reset light path or Reset laser.
Light path monitoring Processing can continue.
Must be acknowledged by means of
Reset light path or Reset laser.
Maintenance Maintenance work is due.
Information Information message (Status in the

laser device has changed.)
Log book Message log book (Configuration

change has taken place.)
Process Process message (fault in the proc-

ess)
Tab. 6-3

CR02

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Operator's manual

TruDisk 3000, TruDisk 3001,

Safe combination of laser device,

Safe combination of laser

TRUMPF Laser GmbH

TRUMPF Laser GmbH

© TRUMPF Laser GmbH

22-24-83-00-EN02 Before you proceed ... I

1 Characteristics of safe combinations 2

2 Dangers due to impermissible combinations 3

3 Information required to assess the safety of 5

4 Examples of safe combinations 8

22-24-83-00-EN02 Table of contents 1

A combination of laser device, laser light cable and focusing

Laser device Optical laser cable Focusing optics

2 Characteristics of safe combinations 22-24-83-00-EN02

Laser radiation escaping

Housing of focusing optics gets hot

2.1 Numerical apertures cannot be

2.2 Wavelength spectrums do not match

22-24-83-00-EN02 Dangers due to impermissible combinations 3

2.3 Focusing optics is not designed for

2.4 Laser light cable or focusing optics

4 Dangers due to impermissible combinations 22-24-83-00-EN02

Information in the user's compartment (example TruDisk Fig. 1

Information on the incoupling optics (example TruDisk FD27) Fig. 2

1 Designation 5 Green border = LLK for green laser

22-24-83-00-EN02 Information required to assess the safety of a 5

Information on LLK-D 100/400 µm NA01 double-core Fig. 5

Depending on the light laser cable, the information on the incou-

1 Information on the incoupling 2 Information on the outcoupling

Information on processing optics (example) Fig. 7

6 Information required to assess the safety of a 22-24-83-00-EN02

Information on programmable focusing optics (example PFO Fig. 8

Information on programmable focusing optics (example Fig. 9

22-24-83-00-EN02 Information required to assess the safety of a 7

The following laser devices, laser light cables and focusing

Laser device Optical laser cable Focusing optics

8 Examples of safe combinations 22-24-83-00-EN02

TruDisk 3000, TruDisk 3001,

TRUMPF Laser GmbH

TRUMPF Laser GmbH

© 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

Further documentation Documents mentioned as reference are part of the delivery of

Safety is important 1‐3

2 Warning instructions 1‐5

5 Safety of the laser product 1‐14

6 Measures of the user 1‐25

Chapter 2 Installation conditions, Transport

1 Scope of delivery 2‐4

3 Weight, floor at the installation site 2‐12

5 Connected loads 2‐17

6 Cooling unit 2‐22

0‐2 Table of contents 2018-04 20-10-06-A3001-

7 Ambient conditions 2‐40

9 Operator’s stand 2‐43

10 Measures to be taken on delivery of the 2‐46

3 Optical arrangement 3‐8

0‐4 Table of contents 2018-04 20-10-06-A3001-

6 Mains distribution 3‐30

7 Laser cooler 3‐32