20-05-15-A1-CR01 - Manual TruDisk4002 (2C) en

Operator's manual
TruDisk 4002
Complement to the operator's
manual
2008-10
Insulation resistance
Insulation resistance
The insulation resistance is the resistance which is measured at an

electric equipment between a phase connection (L1, L2 or L3) and
the protective earth conductor (PE).
The equipment is disconnected from the mains during transport.

The main switch is in ON position.
According to EN 60204, the insulation resistance must be ≥ 1 MΩ.
TRUMPF laser devices can have an insulation resistance < 1 MΩ

when they are delivered. However it is ensured for these laser
devices that the admissible touch voltage is not exceeded in any
case.
Different types of laser devices are listed in the table on the next
page. Among them there are several ones that can have an
insulation resistance < 1 MΩ due to their type of construction. The
table indicates the minimum measuring value which is admissible
for these types. A laser device can be registered with the mark "All
right", if this value is not undershot.
Regular check If you find out during the regular check of the electrical equipment
that a TRUMPF laser device has an insulation resistance < 1 MΩ,
proceed as follows:
1. Look for the minimal insulation resistance admissible for the

laser device in Tab. 1, page 4.
2. If the measured value is higher than the table value, register
and mark the laser device with "All right".
3. If the measured value is lower than the table value, eliminate
the cause for the lower value and repeat the measurement.
One reason might be that a technical modification that
influences the insulation resistance was carried out at the laser
device after delivery.
4. If you cannot find the cause or cannot elimnate it, contact the
TRUMPF service department to agree upon the further
proceeding.
The contact data (phone No. etc) of the service are to be found
in the operator's manual of the laser device.
20-06-00-CR02 2008-10 3
Laser device Minimum admissible insulation resistance
Profiweld 310 kΩ
HL 54P 250 kΩ
HL 101P 260 kΩ
HL 204P 260 kΩ
HL 304P, HL 506P 260 kΩ
HLD 1001.5 1 MΩ
TruDisk 1000 180 kΩ
TruDisk 2002 1 MΩ
TruDisk 3002 1 MΩ
TruDisk 4002 1 MΩ
TruDisk 5001 1 MΩ
TruDisk 6001 1 MΩ
TruDisk 6002 1 MΩ
TruDisk 8002 1 MΩ
TruDisk 10003 1 MΩ
TruMicro 3040 1 MΩ
TruMicro 3140 1 MΩ
TruPulse 21 400 kΩ
TruPulse 33 400 kΩ
TruPulse 44 400 kΩ
TruPulse 62 210 kΩ
TruPulse 74 210 kΩ
TruPulse 103 210 kΩ
TruMark Station 5000 1 MΩ
(TruMark 3000, air cooled)
TruMark Station 5000 450 kΩ
(VectorMark compact 1,
water cooled)
Tab. 1
4 20-06-00-CR02 2008-10
Operator's manual
TruDisk 4002
Edition 2008-01
Order Information Please specify when ordering this document:
Operator's manual
TruDisk 4002
Edition 2008-01
Document number 20-05-15-A1-CR02
Address for orders TRUMPF Laser GmbH + Co. KG

Vertrieb
Aichhalder Straße 39
78713 Schramberg
Fon: +49 (0) 74 22/5 15-0
Fax: +49 (0) 74 22/5 15-4 36
Internet: http://www.trumpf-laser.com
E-Mail: info@de.trumpf-laser.com
Address for service TRUMPF Laser GmbH + Co. KG

Technischer Kundendienst
Aichhalder Straße 39
D-78713 Schramberg
Fon: +49 (0) 74 22/5 15-5 50 cw lasers
Fon: +49 (0) 74 22/5 15-5 60 pulsed lasers
Fon: +49 (0) 74 22/5 15-5 70 marking lasers
Fon: +49 (0) 74 22/5 15-5 85 laser machines
Fon: +49 (0) 74 22/5 15-5 80 spare parts
Fax: +49 (0) 74 22/5 15-1 48
Internet: http://www.trumpf-laser.com
E-Mail: service.yag@de.trumpf-laser.com
E-Mail: spareparts.yag@de.trumpf-laser.com
This document was compiled by the Technical Documentation Dept. of

TRUMPF Laser GmbH + Co. KG.
All rights, in particular the right to reproduce, distribute or translate this docu-
mentation, are reserved to TRUMPF Laser GmbH + Co. KG, even in case of
patent and industrial rights applications. No part of this documentation may be
reproduced, processed, duplicated or distributed by means of electronic sys-
tems in any form whatsoever without the prior written consent of TRUMPF
Laser GmbH + Co. KG Subject to errors and technical changes.
© TRUMPF Laser GmbH + Co. KG
TRUMPF Laser GmbH + Co. KG cannot be held responsible for possible

mistakes in this documentation. Any warranty for direct and indirect damages,
arising in connection with the delivery or the use of this documentation, is
excluded, as far as this is in conformity with the law.
Before you proceed ...
What do the operating in- These operating instructions contain important information on your
structions contain? laser device, its functions, operation and maintenance. This infor-
mation will allow you to operate the laser device safely, avoid any
risks, reduce service costs and break-down times and increase its
reliability and life.
Other regulations In addition to the operating instructions, please also observe the
regulations of your region regarding accident prevention, especially
laser safety, and environmental protection.
Who is the operator’s The operator’s manual of laser device must be read and observed
manual for? by any person who is commissioned with work on the laser device,
for example with:
Operation
Maintenance
Transport.
Safety In chapter 1, you will find general safety instructions for the laser
device.
Installation, transport Chapter 2 contains information required for preparing the installa-
tion site of the laser device and safely transporting the laser devi-
ce.
Description The components of the laser device and their functions are desc-
ribed in chapter 3.
Operation The operating instructions are to be found in chapter 4The ele-

mentary operation steps are described here. Detailed information
on the operation of the software is to be found in the manual to the
operating program The WinLas manual part of documentation for
your laser device.
Maintenance Chapter 5 informs you on maintenance work that you, as the user,
can carry out yourself. In case of further repair and maintenance
work, our Service Department will assist you.
Interruptions of operation Chapter 6 describes finally how to proceed in case of interruptions

of operation caused by technical reasons. This information is
supplemented by messages which are displayed if required on the
user interface.
20-05-15-A1-CR02 2008-01 Before you proceed ... 5

Table of contents
Chapter 1 Safety
1. General notes................................................................. 1-2

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

2.1 Laser light ........................................................................ 1-5
Protective measures against laser light...................... 1-7
Safety circuit ............................................................... 1-8
2.2 Refrigerant ....................................................................... 1-9
2.3 Hazardous materials...................................................... 1-10
Dust, aerosols and gases ......................................... 1-10
Cutting oils ................................................................ 1-11
2.4 Electrical energy ............................................................ 1-13
3. Warning instructions in this manual ......................... 1-14

3.1 Signal words .................................................................. 1-14
3.2 Notes about type, consequences and avoidance of
danger............................................................................ 1-14
Example.................................................................... 1-15
3.3 Symbols ......................................................................... 1-15
Danger signs............................................................. 1-15
Mandatory signs ....................................................... 1-16
4. Designated use of the laser device............................ 1-16
5. Laser beam exit ports.................................................. 1-17
6. Location and function of the safety devices............. 1-18

6.1 Conduct in case of emergency ...................................... 1-18
6.2 EMERGENCY STOP pushbutton.................................. 1-19
6.3 Safety circuits ................................................................ 1-20
6 Table of contents 2008-01 20-05-15-A1-CR02

6.4 Laser warning lamp ....................................................... 1-22
7. Labels and warning signs........................................... 1-23

7.1 Required signs............................................................... 1-23
7.2 Labels on the laser device ............................................. 1-27
7.3 Labels in the area of the focusing optics ....................... 1-28
Chapter 2 Installation conditions, transport

1. Scope of delivery ........................................................... 2-2
1.1 Components of the laser device ...................................... 2-2
1.2 Further accessories ......................................................... 2-3
1.3 Documents....................................................................... 2-3
2. Dimensions .................................................................... 2-4

2.1 Laser device .................................................................... 2-4
2.2 Free spaces for service work........................................... 2-6
2.3 Operating-PC................................................................... 2-7
2.4 Control panel ................................................................... 2-7
2.5 Laser light cable............................................................... 2-8
2.6 Focusing optics................................................................ 2-8
3. Weight, floor at the installation site........................... 2-10
4. Connections ................................................................. 2-11

4.1 External connections ..................................................... 2-11
4.2 Electrical interfaces........................................................ 2-12
4.3 Compressed air connection ........................................... 2-16
5. Electrical connected loads ......................................... 2-17

5.1 Electrical connection...................................................... 2-18
5.2 Electromagnetic compatibility ........................................ 2-19
6. Cooling unit .................................................................. 2-19

6.1 External cooling circuit................................................... 2-19
Cooling water requirement for the tube
dimensioning............................................................. 2-20
6.2 Cooling water connections............................................. 2-23
6.3 Data for chillers.............................................................. 2-24
6.4 Installation examples ..................................................... 2-24
6.5 Laser cooling circuit ....................................................... 2-25
7. Ambient conditions ..................................................... 2-26
20-05-15-A1-CR02 2008-01 Table of contents 7

8. Emissions ..................................................................... 2-27
9. Telepresence................................................................ 2-27
10. Position of the user ..................................................... 2-28

10.1 Position for switching on and off.................................... 2-28
10.2 Position for operating the laser device .......................... 2-28
10.3 Position for setting the focusing optics .......................... 2-29
10.4 Position for maintenance work....................................... 2-30
11. First measures to be taken after receipt of the

laser device .................................................................. 2-30
11.1 Delivery of the laser device............................................ 2-30
11.2 Commissioning .............................................................. 2-31
Removing the shipping brace of the compressor ..... 2-31
Adjusting the level difference.................................... 2-33
12. Transport ...................................................................... 2-33

12.1 Transport by means of pallet jack.................................. 2-33
12.2 Transport by fork lift truck .............................................. 2-35
12.3 Transport by means of a crane...................................... 2-37
12.4 Packing the laser device................................................ 2-39
Chapter 3 Description
1. Overview ......................................................................... 3-2
2. Laser ............................................................................... 3-3

2.1 Design.............................................................................. 3-3
2.2 Specifications................................................................... 3-3
3. Optical arrangement...................................................... 3-4

3.1 Components of the optical arrangement ......................... 3-6
Central shutter (VZ) .................................................... 3-6
Shutter (V1, V2, ...) ..................................................... 3-7
Switch (W1, W2, ...) .................................................... 3-7
Shutter switch (VW1, VW2, ...) ................................... 3-8
Shutter switch with pilot laser ..................................... 3-9
Physical splitter with adjustable splitter ratio ............ 3-10
Deflection (U1, U2, ...) .............................................. 3-11
Deflection 2 x 45° ..................................................... 3-11
Power and energy measuring sensor (LEM)............ 3-12
3.2 Selecting light path ........................................................ 3-12

4. Incoupling optics ......................................................... 3-15
5. Laser light cable (LLK-D) ............................................ 3-16
6. Focusing optics ........................................................... 3-18
7. Control .......................................................................... 3-20
8. The mains distribution ................................................ 3-22
9. Laser cooler ................................................................. 3-24

9.1 Cooling block (Option) ................................................... 3-26
10. Cooling block (Option) ................................................ 3-27
11. Cabinet cooler.............................................................. 3-28
12. Air cleaner .................................................................... 3-30
13. Diode current supplies................................................ 3-32
14. Blow-out device ........................................................... 3-32
15. Operating-PC................................................................ 3-33
16. Control panel................................................................ 3-35
17. WinLas program .......................................................... 3-36

17.1 Functions of the WinLas program.................................. 3-36
17.2 Main screen ................................................................... 3-37
Menu......................................................................... 3-37
Soft keys ................................................................... 3-38
Icon bar..................................................................... 3-39
Power display ........................................................... 3-40
Selecting light path ................................................... 3-40
Status indicator ......................................................... 3-41
17.3 Dialogs ........................................................................... 3-42
Dialog box “Select operating mode” ......................... 3-43
Dialog “Light path overview“ ..................................... 3-44
17.4 User levels ..................................................................... 3-45
Selecting user level................................................... 3-46
18. Telepresence................................................................ 3-47

18.1 Direct connection over an analog modem ..................... 3-47
18.2 Connection via RAS....................................................... 3-48
18.3 Connection via VPN....................................................... 3-48

18.4 User configuration of the operating-PC ......................... 3-49
18.5 Firewall configuration..................................................... 3-49
Chapter 4 Operation
1. Operating elements and indicators ............................. 4-2

1.1 Main switch ...................................................................... 4-2
1.2 Front side of the laser device........................................... 4-3
1.3 Laser warning lamps........................................................ 4-4
1.4 Control panel ................................................................... 4-6
2. Switching the laser device on and off ......................... 4-7

2.1 Switching on .................................................................... 4-7
2.2 Switching off in case of malfunction and
emergencies .................................................................... 4-8
2.3 Switching on after E-STOP.............................................. 4-9
2.4 Switching off after finishing work ..................................... 4-9
3. Operating laser device with WinLas .......................... 4-10

3.1 Selecting operating mode and entering parameters ..... 4-10
3.3 Activating the Laser ....................................................... 4-13
3.4 Responding to messages .............................................. 4-17
3.5 Generating pulse shapes............................................... 4-18
3.6 Creating laser programs ................................................ 4-18
3.7 Programming light paths................................................ 4-19
3.8 Operating pilot laser....................................................... 4-20
Setting pilot laser mode ............................................ 4-20
Switching the pilot laser on and off........................... 4-21
3.9 Program management ................................................... 4-24
Save programs ......................................................... 4-25
4. Controlling the laser device externally...................... 4-25

4.1 Defining the laser power with analog interface.............. 4-26
4.2 Defining the laser power through a field bus
(option)........................................................................... 4-29
4.3 Controlling the laser device functions externally ........... 4-32
Defining the change in laser power .......................... 4-33
4.4 Operating laser device in MixMode ............................... 4-35
4.5 TRUMPF LASERNETWORK (Option) .......................... 4-36

Chapter 5 Maintenance
1. General notes................................................................. 5-4
2. Material ........................................................................... 5-5

2.1 Wearing parts .................................................................. 5-5
2.2 Tools and auxiliaries ........................................................ 5-6
2.3 Consumables................................................................... 5-7
2.4 Disposal ........................................................................... 5-8
3. Opening and closing the laser device ......................... 5-9

3.1 Opening and closing doors .............................................. 5-9
3.2 Opening and closing the door to the user room ............ 5-10
3.3 Opening and closing hoods ........................................... 5-11
3.4 Removing side panel diode power supply ..................... 5-12
4. Hose connections........................................................ 5-13

4.1 Connecting the hose...................................................... 5-13
4.2 Disconnecting the hose ................................................. 5-13
5. Removing the securing device from the stop

valve .............................................................................. 5-14
6. Maintenance overview................................................. 5-15
7. Replacing the pump module....................................... 5-16

7.1 Preparing the laser device ............................................. 5-19
7.2 Removing the pump module.......................................... 5-21
7.3 Inserting the new pump module .................................... 5-24
7.4 Final procedures ............................................................ 5-27
8. Removing and mounting the laser light cable

LLK-D ............................................................................ 5-30
8.1 Removing LLK-D ........................................................... 5-31
8.2 Mounting the LLK-D....................................................... 5-39
9. Maintaining laser light cable ...................................... 5-47

9.1 Cleaning the protective sleeve along with the cover
slide on the LLK-D ......................................................... 5-47
9.2 Replacing the protective sleeve along with the
cover slide...................................................................... 5-48
10. Laser cooler ................................................................. 5-50

10.1 Topping up cooling water............................................... 5-51
10.2 Replacing the water in the tank ..................................... 5-52

10.3 Cleaning the tank........................................................... 5-54
10.4 Replacing the deionizing filter........................................ 5-57
10.5 Cleaning the particle filter .............................................. 5-60
10.6 Replacing filter element in the fine filter......................... 5-62
10.7 Check cooling block (Option)......................................... 5-65
10.8 Maintaining the entry filter.............................................. 5-66
Backfush the entry filter ............................................ 5-66
Clean the entry filter ................................................. 5-67
10.9 Emptying and filling the cooling unit .............................. 5-70
Emptying the cooling unit of the laser device ........... 5-70
Filling the cooling unit ............................................... 5-85
11. Maintenance of the air cleaner ................................... 5-89

11.1 Replacing filter cartridge in the activated carbon
filter ................................................................................ 5-91
11.2 Replacing the filter cartridges in the water
separator and the submircofilter .................................... 5-94
11.3 Filter cartridge in the intake filter ................................... 5-96
11.4 Completely replacing the air cleaner ............................. 5-97
11.5 Changing the filter mat................................................... 5-99
12. Electrics ...................................................................... 5-100

12.1 Identifying blown electrical fuses ................................. 5-100
12.2 Activating an automatic circuit breaker........................ 5-102
12.3 Changing a fuse........................................................... 5-102
12.4 Replacing a microfuse ................................................. 5-104
Chapter 6 Conduct in case of service interruptions
1. Service interruptions..................................................... 6-2

1.1 Measures in case of service interruptions ....................... 6-2
2. Identifying causes ......................................................... 6-3
3. Monitoring and faults .................................................... 6-3

3.1 Monitoring ........................................................................ 6-3
3.2 Fault ................................................................................. 6-5
4. Dealing with messages ................................................. 6-6

4.1 Structure of a message.................................................... 6-6
4.2 Message memory ............................................................ 6-8
Message memory ....................................................... 6-8
Message filter ............................................................. 6-9

Displaying the message text..................................... 6-10
Head of the table ...................................................... 6-10
Type of message ...................................................... 6-10
20-05-15-A1-CR02 2008-01
13
14 2008-01 20-05-15-A1-CR02
Chapter 1
Safety
1. General notes................................................................. 1-3

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

2.1 Laser light ........................................................................ 1-7
Protective measures against laser light...................... 1-9
Safety circuit ............................................................. 1-11
2.2 Hazardous materials...................................................... 1-12
Dust, aerosols and gases ......................................... 1-12
Cutting oils ................................................................ 1-13
2.3 Electrical energy ............................................................ 1-15
20-05-15-A1-CR02 2008-01 Safety 1-1

3. Warning instructions in this manual ......................... 1-16
3.1 Signal words .................................................................. 1-16
3.2 Notes about type, consequences and avoidance of
danger............................................................................ 1-17
Example.................................................................... 1-17
3.3 Symbols ......................................................................... 1-17
Danger signs............................................................. 1-17
Mandatory signs ....................................................... 1-18
4. Designated use of the laser device............................ 1-19
5. Laser beam exit ports.................................................. 1-20
6. Location and function of the safety devices............. 1-21

6.1 EMERGENCY STOP pushbutton.................................. 1-21
6.2 Safety circuits ................................................................ 1-22
6.3 Laser warning lamp ....................................................... 1-24
6.4 Conduct in case of emergency ...................................... 1-25
7. Labels and warning signs........................................... 1-26

7.1 Required signs............................................................... 1-26
7.2 Labels on the laser device ............................................. 1-30
7.3 Labels in the area of the focusing optics ....................... 1-31
1-2 Safety 2008-01 20-05-15-A1-CR02

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

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

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

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

it is in technically perfect condition.
it is used in accordance with its designated use (see "De-
signated use of the laser device", pg. 1-19).
the user is aware of the safety factors and risks.
the instructions set out in this manual are followed.
Any functional disorders, especially those affecting the safety of

the unit, should be rectified immediately!
20-05-15-A1-CR02 2008-01 General notes 1-3

1.2 Safety instructions for certain opera-
ting stages
Normal operation
Operate the laser device only when all protective and safety rele-
vant devices, e.g. removable safety devices, E-Stop equipment,
exhausters, are in place and fully operative.
Immediately switch off the laser device in case of malfunctions and
secure it against unintentional restart. Have any defects rectified
immediately.
Upkeep
Adhere to the setting, maintenance and inspection activities and

their schedules prescribed in the operator's manual. Pay attention
to notes regarding the
replacement of parts.
Maintenance work should be only carried out by trained persons.
Check the safety devices of the laser device and their properly
functioning regularly.
1.3 Selection and qualification of staff
User’s obligation The user must only entrust trained and instructed staff with opera-
tion, setup, maintenance and upkeep of the laser device. Set out
clearly the individual responsibilities of the persons for operation,
setup, maintenance and upkeep.
Skilled electrician Any work on the electrical equipment of the laser device must be
carried out only by a skilled electrician or by instructed persons
under the supervision and guidance of a skilled electrician and in
accordance with electrical engineering rules and regulations.
1-4 General notes 2008-01 20-05-15-A1-CR02

1.4 Organizational measures
These operating instructions must always be at hand at the place

where the laser device is used.
Accident prevention, In addition to the operating instructions, observe all other generally
environmental protection applicable legal and other mandatory regulations relevant to acci-
dent prevention and environment protection and instruct all per-
sons commissioned with this work correspondingly. Some impor-
tant standards and regulations are listed in this chapter (see
"Standards and regulations").
Reading the operator's Before starting the work, the personnel entrusted with work on the
manual laser device must have read the operator’s manual and chapter 1
"Safety" in particular. This applies especially to persons working
only occasionally on the laser device, e.g. during maintenance.
Safety goggles As far as required or stipulated by instructions, use laser safety

goggles.
Labels Observe all safety instructions and warning indications attached to

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

laser device which may affect safety without approval by TRUMPF
Laser cannot be held liable for any damage resulting from such
modifications. The risk lies entirely with the user.
Spare parts Spare parts must comply with the technical requirements specified
by TRUMPF Laser. This is always guaranteed with original spare
parts.
Program alterations Do not alter the program (software) of programmable control sys-
tems.
Software-Installation Do not install a software which is not explicitly approved for instal-
lation by TRUMPF Laser. TRUMPF Laser cannot be held liable for
damage resulting from the installation or operation of software not
approved by TRUMPF Laser.
20-05-15-A1-CR02 2008-01 General notes 1-5

1.5 Documents
Standards and regulations
In the following, some important standards and regulations are

listed, which should be observed when operating a laser unit. This
list is, however, purely informative. TRUMPF Laser does not as-
sume any responsibility for the completeness of this list.
International standards Standard Name

IEC 825 Radiation safety of laser products
Filters and eye protection devices against laser radia-
EN 207
tion (laser safety goggles)
EN 954-1 Safety-related parts of control systems
EN 60204 Electrical equipment of industrial machines
EN 60825 Radiation protection of laser units
Tab. 1-1
Enclosed documents
The following documents concerning "safety" are attached to this

manual:
Accident prevention regulation "Laserstrahlung" BGV B 2 (pre-
vious VBG 93).
Information about registration of laser devices.
Interface descriptions.
Supplementary laser warning signs.

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

infrared spectral range. This radiation may be hazardous to eyes
and skin.
The most important protection measures for the handling of laser
radiation are defined in the accident prevention regulations "Laser
radiation" (BGV B 2, formerly VBG 93). These accident prevention
regulations refer to the standard EN 60825 "Safety of laser devi-
ces", available as international harmonized standard IEC 825.
Laser classes An important aspect of the regulations is the classification of laser

equipment into certain laser classes, dependent on the hazards
generated by the emitted laser radiation.
The definition of the laser classes is described briefly below. The
precise definition listing limit values can be found in EN 60825.
Class 1 Class 1 means that the laser device is not dangerous in standard
operation with regard to the laser radiation. If observing laser light
through optical instruments is dangerous, then the laser is classi-
fied as class 1M.
TRUMPF Laser achieves class 1 for laser devices by assembling
suitable protective casings and protection covers.The laser device
is classified as class 4 during maintenance and servicing with open
protective casing and with bridged safety switch
Class 2 Class 2 means that the laser emits radiation in the visible wave-
length range (400 – 700 nm). The radiation is not harmful to the
human eye, even when observing it through optical instruments.
The eye lid reflex usually protects the eye when looking into the
beam directly. If observing it through optical instruments is dange-
rous, then the laser is classified as class 2M.
20-05-15-A1-CR02 2008-01 Information on special risks 1-7

Class 3R Class 3R means that the laser emits radiation in the wavelength
range from 302.5 nm to 106 nm. A direct look into the beam may be
dangerous. The risk is, however, less than with Class 3B lasers.
Class 3B Class 3B means that the direct or mirrored beam is dangerous.

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

Laser device with closed hood 1
Laser device with open hood 4
Laser light cable 1
Focusing optics under a closed protective cover 1
Fokusing 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 2
Tab. 1-2
1-8 Information on special risks 2008-01 20-05-15-A1-CR02

Protective measures against laser light
Eyes and skin may be exposed to laser radiation, if the laser

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

Proceed in accordance with the laws and regulations applicable in your regi-
on, when operating laser devices.
Tab. 1-3
Classes 4 and 3B Labeling the workstation

As user, you are responsible for the corresponding labeling of the workstati-
on.
The following picture illustrates the label for a class 4 laser device.
Tab. 1-4
Summon the laser security officer

Furthermore you have to appoint in writing experts as laser security officers
when operating classes 3B and 4 laser devices. Upkeep also forms part of
operation.
Tab. 1-5
Wear laser safety goggles

The laser safety goggles must protect the eyes from the wavelengths of the
laser light used: for Yb:YAG lasers 1030 nm, for Nd:YAG lasers 1064 nm, for
fiber lasers 1085 nm.
The laser safety goggles protect only against diffuse scattered light and
the wave length of the pump light used. Thus, never look into the direct
beam or reflected beam even when wearing laser safety goggles.
Tab. 1-6
Keep body parts away from the beam guideway in the area of the laser
exit opening
High-power laser light can cause serious burns on the skin or clothing.
Tab. 1-7

Secure the laser area against the entry of unprotected people
Prevent the access of unprotected persons to the processing station by ap-
propriate safety measures, e.g. by card reader or barrier systems.
Tab. 1-8
Register the laser device

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

When working at laser installation, wear adjustment goggles protecting
yourself against the wave length of the laser light in use.
Tab. 1-10
Secure the area against the access of unprotected persons

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

The incidence of laser light on the unprotected eye may damage the retina
irreparably.
Tab. 1-12
Class 1
According to definition, class 1 laser units are harmless. Persons are not
required to take protective measures.
Tab. 1-13

Safety circuit
If you have integrated the laser device into a unit with laser shiel-
ding cover, ensure that the laser shielding cover is included in the
safety circuit of the laser device. The safety circuit ensures that
laser light can only be emitted from the focusing lens if the laser
protective cover is closed.
The corresponding information is to be found in section "Safety
circuits" of this chapter and in the interface description.
If you operate the laser device without laser protective cover, the
workstation is assigned to the laser class 4. In that case, please
take the necessary protective measures in the danger area of the
laser device.

2.2 Hazardous materials
Especially when handling hazardous materials, we expressly point

out that we can only give examples of danger sources. As the
operator of the unit, you have to estimate the possible danger po-
tential of the materials to be processed and to check and introduce
necessary measures.
For precautionary reasons and independently of the necessary
extraction and filtering devices of the exhaust air duct, it is recom-
mended to provide for a sufficient supply of fresh air in the working
area. In this connection we refer to the TRGS standard (“Technical
regulations for hazardous substances”).
Emission of particles when the extraction system is not

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

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

on the (processing) speed and the cutting gas pressure, if appli-
cable. The emission is minimal in the case of optimum parameters.
In addition to the cutting parameters, the type of material has a
strong influence on the emission.
When processing mild steel, the emission is remarkably lower than
with Cr-Ni materials or galvanized steel sheets. When processing
metallic materials with a laser, aerosol and dust are produced,
97 % of which have a diameter of < 5.7 m.

Note
Depending on the utilization of the laser device, carcinogenic sub-
stances can be emitted, depending on the materials processed. If
there is such a risk, the operator has to carry out his own measu-
rements and to take protective measures for the personnel, if re-
quired.
Depending on the utilization of the laser device, carcinogenic sub-

stances can be emitted, depending on the materials processed. If
there is such a risk, the operator has to carry out his own measu-
rements and to take protective measures for the personnel, if re-
quired.
In the metallic sector, carcinogenic substances according to TRGS

560 are for example:
beryllium compounds
chromium/nickel compounds
zinc chromates.
Cutting oils
When treating metallic materials with cutting oils, hydrocarbons

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

TLV (mg/m3)
sheet (mg/m3) (mg/m3)
Acetaldehyde 0,007 0,005 90
Acetone 0,111 0,204 2400
Butanol 0,334 0,022 300
Butyl acetate 0,081 0,007 950
Decane 0,060 0,004 no limit value
Ethyl acetate 0,237 0,002 1400
Ethylbenzene 0,034 0,004 440
Formaldehyde 0,021 0,013 0,6
All hydrocarbons 2,600 1,875 no limit value
Toluene 0,057 0,12 380
Xylene 0,113 0,013 440
Cutting oils Tab. 1-14
In these cases, the values fall distinctly short of the maximum al-
lowable concentrations (TLV values) (examples of the use of other
cutting oils are not directly applicable).

Cutting oils for aluminum processing – such as the oil of the com-
pany Wisura recommended by TRUMPF Laser – contain amine
components so that nitrosamines could theoretically be formed
during laser processing.
However, investigations to that effect showed a negative result in
all tests: Nitrosamines could not be detected.
When using the cutting oils on a chlorine-free basis, recommended
by TRUMPF, the generation of polychlorinated biphenylene
(PCB) and dioxins can be excluded.
Polyethylene-coated sheets When sheets coated with polyethylene films are cut by laser,
mainly aliphatic and olefinic compounds are released:
n-heptane, 1-heptene, heptadiene
n-octane, 1-octene, octadiene
n-nonane, 1-nonene, nonadiene
n-decane, 1-decene, decadiene
n-undecane, 1-undecene, undecadiene
further n-alkane, 1-alkene, diene pairs
Toluene
Ethylbenzene
L-limonene
N-butylbenzenesulfonamide
During measurements in the extracted air flow by means of a total

hydrocarbon analyzer (FID), methane concentrations between 2
and 10 ppm were found.
Therefore, it is not to be expected that limits are exceeded by or-
ganic exhaust air components when polyethylene-coated sheets
are processed by laser. Bad smell may be caused by individual
very low concentrations (ppb range) of odor-intensive exhaust air
components.

2.3 Electrical energy
While carrying out upkeep work, you can come into contact
with dangerous live parts!
Touching live electric parts can be extremely dangerous.
Any work on the electric equipment must be carried out only
Danger
by a trained electrician.
Switch off the laser device prior to any upkeep work.
Secure the laser device against restart.
Before touching electric parts, first check if they are
de-energized.
Malfunctions In case of malfunctions, switch off the electrical energy supply of

the laser device immediately (switch off the main switch).
Stationary device In terms of the safety regulations for the protection against electric
energy, the laser device is a stationary device. Accordingly the
safety standards and accident prevention regulations relevant to
stationary devices are applicable.
This means for you as the operating company:

The laser device must not be moved when it is switched on.
Regular check The electrical safety of the device must be checked regularly, at
least every 4 years. The basis for the check is the German stan-
dard DIN VDE 0702. Outside the scope of this standard, the regu-
lations relevant in the respective region are applicable.
The check must be carried out by a skilled electrician. It contains

among other things the following actions:
visual check, e.g. state of the ground wire and its connection
point.
checking the ground wire resistance.
Fuses Use only original fuses with the specified characteristics and cur-
rent rating.
Voltage when main switch Some components are still under dangerous voltage, even if the
is off main switch is in position OFF. Therefore check first that the parts
that you will touch are dead.
Energy storages The discharge time of energy storages (capacitors) may be more
than 1 minute. Check the parts which are live during operation for
the presence of voltage, also after having switched off the machi-
ne. Start the work on live parts only after you have checked that
their power supply has been cut off.

3. Warning instructions in this manual
When operating the laser device also actions have to be carried

out, from which dangers may arise. In this operator's manual war-
ning hints precede the instructions for the execution of such ac-
tions.
The warning hints contain:

a signal word.
hints about type and source of the danger.
instructions how to avoid danger.
Pay attention to the warning hints!

Follow the commandments and the interdictions of the warning
hints. They serve for your protection.
Form and contents of the warning hints are described in the follo-
wing sections.
3.1 Signal words
The warning instructions are identified by one of the following sig-

nal words:
Danger
Warning
Caution
The signal words have the following meaning:
Danger "Danger" indicates great danger. If not avoided, it leads to death or

serious injuries.
Warning "Warning" indicates a dangerous situation. If not avoided, it can

lead to serious injury or considerable damage to material property.
Caution "Caution" indicates a possibly dangerous situation. If not avoided, it

can lead to light injuries or light damages to material property.
1-16 Warning instructions in this manual 2008-01 20-05-15-A1-CR02

3.2 Notes about type, consequences and
avoidance of danger
The warning instructions contain indications about type of the

danger, possible consequences and instructions for the operator
how to avoid the danger.
Example
Type of danger "Your eyes may be exposed to laser light during operation."
Possible consequences "Laser light can irreparably damage your eyes."
Instructions on how to "Do not reach into the beam guideway!"

behave "Wear laser safety goggles!"
3.3 Symbols
Danger signs
Some warning instructions are complemented by symbols in the

margin which indicate the type of danger.
Fig. 1-1
General danger sign. The type of danger is designated more clo-

sely in the warning hint marked accordingly.
Fig. 1-2
This sign warns against dangerous laser beams.
20-05-15-A1-CR02 2008-01 Warning instructions in this manual 1-17

Fig. 1-3
This sign warns against electric voltage.
Mandatory signs
A mandatory sign is added to the instructions, if the action to be

carried out requires the wearing of personal protection clothes.
Fig. 1-4
This sign requests you to wear protection for the eyes. The type of
protection for the eyes is further specified in the text of the warning
instruction (e.g. laser safety goggles).
Fig. 1-5
This sign requires you to wear protective gloves.
Fig. 1-6
This sign requires you to wear a hard hat.
1-18 Warning instructions in this manual 2008-01 20-05-15-A1-CR02

4. Designated use of the laser device
The laser device has been designed exclusively for processing

solid metals or metal alloys.
Operating the device within the limits of its designated use requires
you to:
observe the instructions set out in this operating manual.
wire and connect electric lines to the laser device in complian-
ce with the regulations regarding electromagnetic compatibility
(EMC).
not to move the laser device when it is switched on.
carry out necessary inspections and maintenance work.
Exceptions The laser device is not designated for processing metals or metal
alloys in connection with flammable or explosive materials
(example: containers filled with combustible gas or fuel, ammuniti-
on).
The laser device must not be operated in an explosion-prone envi-
ronment.
The manufacturer cannot be held liable for any damage resulting
from such use. The risk lies entirely with the user.
20-05-15-A1-CR02 2008-01 Designated use of the laser device 1-19

5. Laser beam exit ports
Fig. 1-7
The figure shows a laser device with focusing optics. The arrow
marks the place where the laser light is emitted.
Focusing optics are assembled by modules, your application re-
quires. The appearance may differ from the optics shown in the
picture. More than one laser light cable and focusing optics can be
connected to a laser device. In any case, the laser light is emitted
from the lenses of the focusing optics.
Laser light cannot be emitted from other places of the laser device
if all protective covers are closed.
Wave lengths Laser Wave length Spectral range

Yb:YAG 1030 nm near infrared
pilot laser 635 – 650 nm visible, red
Tab. 1-16
If you operate the focusing optics with detached protective cover

(laser product class 4), make sure that all persons who may be in
danger wear safety goggles. The laser safety goggles must have
filtering glasses suitable for the wavelength of the laser light.
1-20 Laser beam exit ports 2008-01 20-05-15-A1-CR02

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

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

on the control panel.
on the front of the laser device.
Fig. 1-8
Operating the "E-Stop" pushbutton immediately stops all compo-

nents of the laser device which can be dangerous. In particular, no
laser light may be emitted any longer after having operated the
E-Stop pushbutton.
Note
The control panel should be attached in a place, where it can easi-
ly be reached from the operator's position. This guarantees that the
E-Stop pushbutton can be pressed immediately in case of an
emergency situation.
20-05-15-A1-CR02 2008-01 Location and function of the safety devices 1-21

Further pushbuttons Further E-Stop pushbuttons can be additionally connected to the
laser device. Integration of the E-Stop circuit of the laser device in
an E-Stop circuit of the system is also possible. For further infor-
mation, see the interface description for E-Stop.
Checking the function Check the function of the E-Stop pushbuttons if you have modified
the E-Stop circuit of the laser device. TRUMPF Laser cannot be
held liable for any damage resulting from the incorrect wiring of the
E-Stop circuit.
6.2 Safety circuits
The control of the laser device contains interfaces for safety circu-
its (SIK).
What is a safety circuit? A safety circuit is an electric circuit used for monitoring the protec-
tive covers and safety doors. Under the protective cover monitored
by the safety circuit, laser light can only be emitted if the laser pro-
tective cover is closed.
Purpose Safety circuits allow entire systems to be operated as class 1 laser

devices.
ASV board Each safety circuit is connected to an ASV board, which is located
in the control of the laser device. The ASV board controls the opti-
cal shutter, which prevents the emission of laser light when the
safety circuit is open.
ASV: Operating and safety shutter (German for: Arbeits- und Si-
cherheits-Verschluss.)
Further information The following picture shows the basic function of a safety circuit.
1-22 Location and function of the safety devices 2008-01 20-05-15-A1-CR02

1 Laser control 3 Door contact closed
2 Shutter 4 Door contact open
Safety circuit, principle Fig. 1-9
Work function In the picture above the safety circuit is closed. The laser opera-
tes according to the running laser program or is controlled manual-
ly by the operator.
Safety function In the picture below, the safety circuit is open because the door
of the protective cabin was opened. The shutter is changed to
CLOSED position via the ASV board in the control. No laser light is
emitted at the processing point anymore. In the absorber the laser
light is converted into heat.

6.3 Laser warning lamp
Laser warning lamp on top of the laser device Fig. 1-10
Two laser warning lamps are fitted at the outside of the laser devi-
ce.
Another laser warning lamp is covered by the hood and becomes
active when the hood is open.
Laser warning lamp in the laser device Fig. 1-11
The laser warning lamp lights if:

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 A further laser warning lamp can be connected to the laser device
and attached, e.g. near the workstation.
Further information can be found in the interface description for
E-STOP and ASV.
1-24 Location and function of the safety devices 2008-01 20-05-15-A1-CR02

6.4 Conduct in case of emergency
WS-71042
1 E-Stop pushbutton on the 3 E-Stop pushbutton on the front
control panel of the laser device
2 Main switch
Fig. 1-12
1. Immediately press one E-Stop push-button (1 or 3).

2. If you are not sure that all dangers have been averted: Turn
main switch to the OFF position (2).
If the laser device is integrated in a system there may be more
devices for switching off. Please refer to the documents included in
the delivery of the system.

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

device and in the area of the focusing optics, are described in this
section. Each label indicates the place where it is located.
7.1 Required signs
Warning against dangerous laser radiation Fig. 1-13
Laser class 1
According to 60825-1:2003-10
19-02-09-02
Reference to laser product class Fig. 1-14
Po
Notes regarding power and wavelength of the pilot Fig. 1-15

laser
Notes regarding power and wavelength of the pilot Fig. 1-16

laser
1-26 Labels and warning signs 2008-01 20-05-15-A1-CR02

E
CAUTION !
Invisible Laser radiation may emerge,
if the cover is open and the bridging
key is inserted. Avoid eye or skin
exposure to direct or scattered radiation !
19-02-10-06
Notes regarding power and wavelength of the laser Fig. 1-18
Invisible and visible laser radiation

Avoid eye or skin exposure to
direct or scattered radiation
Laser class 4
19-02-10-09 EN 60825-1:2001-11
Rating plate of the laser device (example) Fig. 1-20
Warning against touching of surfaces at the pump module Fig. 1-21
20-05-15-A1-CR02 2008-01 Labels and warning signs 1-27

J
Warning against dangerous electric voltage Fig. 1-22
Hochspannung ! Lebensgefahr !
High voltage ! Danger to Live !
Haute tension ! Danger de mort !
Warning against dangerous electric voltage Fig. 1-23
Type plate of the laser device Fig. 1-24
Bei ausgeschaltetem Sous tension même

Hauptschalter en position d'arrêt de
unter Spannung l’interrupteur principal
Voltage also present Con el interruptor

when main principal desconectado se
switch is turned off encuentra bajo tensión
Warning against dangerous electric voltage when the Fig. 1-25

main switch is switched off

N
05-06-02-55
Note: "Drain the cooling water in case of frost risk", Fig. 1-26
instructions: see operator's manual
Warning against high leakage current in the ground Fig. 1-27

wire
Warning against hot surface Fig. 1-28

7.2 Labels on the laser device
The following picture shows the location of the labels on the laser
devices. The letters are the same as those shown in section "Re-
quired signs".
A E FG
H
I
D
C
A
B
I
J
N
O
P K M
Fig. 1-30

7.3 Labels in the area of the focusing op-
tics
Upon delivery, the label "Avoid Exposure" is enclosed in triplicate.

The labels are adhesive labels with removable protective film.
The labels will not be attached yet, as the arrangement of the sta-
tion where the focusing optics are to be fitted to, is normally not
known at the time of delivery.
Obligation to identify As user of the laser device you are obliged to attach labels near
the focusing optics, so that they can be seen by the persons stay-
ing within this area.

Chapter 2
Installation conditions,
transport
1. Scope of delivery ........................................................... 2-3

1.1 Components of the laser device ...................................... 2-4
1.2 Further accessories ......................................................... 2-5
1.3 Documents....................................................................... 2-5
2. Dimensions .................................................................... 2-6

2.1 Laser device .................................................................... 2-6
2.2 Free spaces for service work........................................... 2-8
2.3 Operating-PC................................................................... 2-9
2.4 Control panel ................................................................... 2-9
2.5 Laser light cable............................................................. 2-10
2.6 Focusing optics.............................................................. 2-11
3. Weight, floor at the installation site........................... 2-13
4. Connections ................................................................. 2-14

4.1 External connections ..................................................... 2-14
4.2 Electrical interfaces........................................................ 2-16
4.3 Compressed air connection ........................................... 2-20
20-05-15-A1-CR02 2008-01 Installation conditions, transport 2-1

5. Electrical connected loads ......................................... 2-21
5.1 Electrical connection...................................................... 2-22
5.2 Electromagnetic compatibility ........................................ 2-23
6. Cooling unit .................................................................. 2-24

6.1 External cooling circuit................................................... 2-24
Cooling water requirement for the tube
dimensioning............................................................. 2-24
6.2 Cooling water connections............................................. 2-27
6.3 Data for chillers.............................................................. 2-28
6.4 Installation examples ..................................................... 2-29
6.5 Laser cooling circuit ....................................................... 2-30
7. Ambient conditions ..................................................... 2-31
8. Emissions ..................................................................... 2-32
9. Telepresence................................................................ 2-32
10. Position of the user ..................................................... 2-33

10.1 Position for switching on and off.................................... 2-33
10.2 Position for operating the laser device .......................... 2-33
10.3 Position for setting the focusing optics .......................... 2-34
10.4 Position for maintenance work....................................... 2-34
11. First measures to be taken after receipt of the

laser device .................................................................. 2-35
11.1 Delivery of the laser device............................................ 2-35
11.2 Commissioning .............................................................. 2-35
Removing the shipping brace of the compressor ..... 2-36
Adjusting the level difference.................................... 2-37
12. Transport ...................................................................... 2-38

12.1 Transport by means of pallet jack.................................. 2-38
12.2 Transport by fork lift truck .............................................. 2-40
12.3 Transport by means of a crane...................................... 2-42
12.4 Packing the laser device................................................ 2-44
2-2 Installation conditions, transport 2008-01 20-05-15-A1-CR02

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

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

the basic scope of delivery.
important optional components.
documents which are included in the delivery.
The total scope of delivery is listed on the delivery note. This note
contains additional information which can be important for the iden-
tification of components, e.g. material numbers.
The components are described in chapter "Description".
20-05-15-A1-CR02 2008-01 Scope of delivery 2-3

1.1 Components of the laser device
1 Laser device 3 Control panel

2 Operating-PC
Fig. 2-1
Operating-PC A desktop PC is part of the scope of delivery. On demand it is pos-

sible to provide an industrial PC.
Control panel The laser control is switched on/off by means of the control panel.
With the switch E-Stop it is possible to stop the laser immediately
in case of danger.
The functions of the contol panel can also be carried out by an
external control e.g. a PLC. Details on this subject are to be found
in the interface descriptions of the laser device.
Chiller A chiller can optionally be included in the scope of delivery.
2-4 Scope of delivery 2008-01 20-05-15-A1-CR02

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

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

Operator's manual.
Software manual.
Interface descriptions.
Dimensional drawing, e.g. focusing optics.
Manufacturer’s declaration or declaration of conformity.
Acceptance certificate.
Circuit documentation for the service of TRUMPF Laser.
Labels and warning signs which have to be attached to the
workstation.
Optional: Documentation of externally-bought components
for example:
– operating instructions for a CCD camera which is operated
on a focusing optics.
– documentation of the chiller.
20-05-15-A1-CR02 2008-01 Scope of delivery 2-5

2. Dimensions
2.1 Laser device
274
420 574
1410
2890
Front view Fig. 2-3
56
0
205 340
1300
Left side view Fig. 2-4
2-6 Dimensions 2008-01 20-05-15-A1-CR02

2890
625
585
4 85
55
5
5
72
Top view Fig. 2-5
1420 420
1860
Top view, position and size of the adjustable legs Fig. 2-6
20-05-15-A1-CR02 2008-01 Dimensions 2-7

2.2 Free spaces for service work
Free space around the laser device Fig. 2-7
The laser device must be accessible from all sides for service
work. Furthermore space for tools and measuring instruments is
required in most cases.
The indicated spaces show the minimum spaces that must be free
around the laser device.
2-8 Dimensions 2008-01 20-05-15-A1-CR02

2.3 Operating-PC
Fig. 2-8
A desktop PC is part of the delivery volume. On demand an indus-

trial PC can be supplied. Dimensions and technical data depend on
the type respectively used.
An appropriate installation site must be prepared for the operating
PC.
2.4 Control panel
118
Fig. 2-9
20-05-15-A1-CR02 2008-01 Dimensions 2-9

2.5 Laser light cable
Fig. 2-10
Length The length of the laser light cable depends on the distance bet-
ween laser device and focusing optics.
The documents for the laser device contain specifications on the
dimensions of the laser light cable.
Bending radius The bending radius of the laser cable must not be smaller than
200 mm.
Installation Corresponding ways and surfaces must be prepared for the instal-
lation of the laser light cable.
Laser light cables must be laid without traction, kinks and torsion.
2-10 Dimensions 2008-01 20-05-15-A1-CR02

2.6 Focusing optics
Focusing optics are made up of modules as required by the pro-

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

can be found in the following documentation:
operating manual of your focusing optics.
dimensional drawing of your focusing optics.
installation directive.
These documents have been delivered together with your laser

device or with the separately delivered focusing optics.
Dimensional drawing and The dimensional drawing contains:

installation directive all dimensions in millimeters [mm].
letters as a reference to the installation directive.
How to use the dimensional drawing and the installation instructi-

ons is illustrated on the next page.
20-05-15-A1-CR02 2008-01 Dimensions 2-11

371,5 134,5
Kamerama ße
37 54,5 ±3 abhängig vom Typ
10
k
p
360°
8
drehbar
Schraube 7,5
f M5 (4x)
h b a
Seriennu mm er CFO
7 9 1 min Biegeradius R200 Identnum m er CFO
6
Brennweiten-
e 2
kennzeichnung
Objektiv
C 11
r
3
130 ±0,01 2,3,4
Ansicht C K ühlwasser
r Zulauf
4x90° 12
drehbar
Zuluft 22
Crossjet 13
14
4x90 °
5 drehbar
Loch - 19
6
<1 15 8x45 °
drehbar
X 0,2
Schutzgas / Sp ülgas 37 37
K ühlwasser
Y 0,2
Z R ücklauf 77 ±0,20
39 52 ±0,20 d 1 1237676 22-43-29-00 Steckeraufnah
me CFO 8 0778143 22-27-04-00 Beobachtung drehbar
2 1285521 22-47-05-00 mation CFO 200 AQ mit Defok. 9
Kolli 0778149 22-27-06-00 Adapter fuermera
Ka
3 0781581 22-24-78-00 Kuehlring 3 10 Ka
mera
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
modul CFO 50
6 0766534 22-24-03-00 Wuerfel°90fuer 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 Schutzvermerk nach CFO

f=200 DIN 34 beachten! (mit LLK dargestellt)
Abbildungs- Gewicht ohne LLK TRUMPF Laser Blatt 1
verh ä ltnis
a bis z siehe Einbaur
ichtlinieXX-XX-XX-DH 1:1 ca. 5,5 kg G m bH + Co. KG
D - 78713
von 1 Bl.
Index Datum bearb. gepr. freigg.Schra m berg
Dimensional drawing of an focusing optics (example) Fig. 2-11
In addition to the dimensions, you will also find letters on the dra-
wing. The arrow points to the letter e.
Under "e" you will find in the installation directive the dimensional
drawing for the holes "Würfel 90°".
Dimensional drawing for "Würfel 90°" in the installation Fig. 2-12

directive
2-12 Dimensions 2008-01 20-05-15-A1-CR02

3. Weight, floor at the installation site
Weight without cooling block: 19 kN (1900 kg) with cooling

Weight laser device block: 21 kN (2100 kg)
Distributed on 4 adjustable legs Ø 80 mm
Charge per ad- without cooling block: ca. 4,75 kN (ca. 475 kg)
justable leg: with cooling block: ca. 5,25 kN (ca. 525 kg)
Tab. 2-1
Height difference at the floor Place the laser device as horizontally as possible! Height differ-
ences of the floor at the installation site can be compensated with
the adjustable legs (see "Adjusting the level difference", pg. 2-37).
Vibrating charge Maximum vibrating charge in vertical direction:

Vibrating acceleration 0,01 g ≙ 100 mm/s²
Vibration amplitude 0,6 mm/s
Tab. 2-2
If there is a higher vibrating charge at the installation site, vibration

dampers must be used. For the dimensioning of the vibration
dampers, a vibration measurement is required at the installation
site.
20-05-15-A1-CR02 2008-01 Weight, floor at the installation site 2-13

4. Connections
4.1 External connections
1 2
4 5 6 5 7 8 9
1 Compressed air connection 4 Cooling water return 7 Cooling water supply

2 Condensate drain hose 5 Water drain hoses cooling water 8 Control panel
3 Electrical supply mains cable 6 Water drain hose base 9 Ethernet cable to the opera-
ting-PC
Fig. 2-13
2-14 Connections 2008-01 20-05-15-A1-CR02

Compressed air connection If the cooler of the laser device shall be emptied (e.g. before
transport or for a longer period of storage), the laser device must
be supplied with compressed air to operate the blow-off device.
Further information to the compressed air connection: (see
"Compressed air connection ", pg. 2-20).
Condensate drain hose The laser device is provided with an air cleaner. The condensate
accruing from the air cleaner (less than 1 liter per day) is drained
out of the laser device.
Cable grommet mains cable The laser device is supplied with electric energy via a mains cable.
The mains cable is inserted into the laser device through the cable
grommet and connected to the mains supply unit.
Further information: (see "Electrical connected loads", pg. 2-21).
Cooling water supply and The cooling water hoses are mounted on a hose sleeve. The hose
return sleeve is screwed into a connection piece which is attached to the
laser device by means of a union nut.
Information on the thread and wrench dimensions for the cooling
water connections: (see "Cooling unit", pg. 2-24).
Control panel The cable of the control panel is inserted into the laser device
through the cable grommet. The plug at the end of the cable is
connected to the mains distribution.
Further information on the connection of the control panel is con-
tained in the interface descriptions of the laser device.
Note
Lay the cable to the control panel in such a way that it is not expo-
sed to any risk by crushing or being run over.
Cable to the operating PC Plug at the projecting end: RJ-45.

Further information on the operating PC is contained in section
"Electrical interfaces".
20-05-15-A1-CR02 2008-01 Connections 2-15

4.2 Electrical interfaces
This chapter describes the electrical interfaces that can be used to

connect the laser device with other equipment. Further information
can be found in the interface descriptions.
3
5
4
1 Interface of the IFO-box for the 3 Interface for LLK-monitoring 5 Interface of a gateway for the
connection of a FO-cable to the connection of a Fieldbus cable
focusing optics for the external control
2 Laser light cable (LLK) 4 Interface for SIK-cables or
LLK-coding cables
Fig. 2-14
Interface of an IFO-box An IFO-box (Option) is the interface between a board IIO in the
control of the laser device and a focusing optics. A FO cable led in
parallel to the appertaining laser light cable (LLK) of a light path is
connected to the connector of the IFO-box.
The connected focusing optics is controlled and monitored via the
connected board IIO of the control.
2-16 Connections 2008-01 20-05-15-A1-CR02

Laser light cable (LLK) In connection with the ILN-boxes (Option) in the user compartment
it is also possible to replace laser light cables while the laser stays
available for other light paths. The light path of a LLK to be repla-
ced is blocked automatically, when the safety connector for the
lifting of the locking at the incoupling optics is removed.
Without ILN boxes, the laser is automatically switched off when
replacing the LLK.
Interface for LLK-monitoring The electric cable of the appertaining LLK connector is connected
at the connector for the LLK monitoring in the user compartment.
The LLKs are monitored by the ILN boxes in connection with
ILN-boxes (Option) in the user compartment. Only the appertaining
light path is blocked by unplugging a LLK-monitoring cable.
Without ILN-boxes, the laser is automatically switched off when
unplugging a LLK-monitoring cable.
Interface description for This interface is only available in connection with ILN-boxes (Opti-
SIK-cable or LLK coding on) in the user compartment.
cable
At the connector it is possible to connect:
SIK-cable that is led in parallel to the LLK into the processing
station in case of Fieldbus coded light paths (TLN-fc).
LLK-coding cable that is led in parallel to the LLK into the pro-
cessing station in case of LLK-coded light paths (ILN).
In a SIK-cable there are led:

2-channel safety circuit.
2 status signals via relay contacts.
In a LLK-coding cable are led:

2-channel safety circuit.
2 status signals via relay contacts.
Lines for the coding of the laser device and the light path.
Interface for Fieldbus cables In connection with gateways (Option), in the user compartment it is
possible to realize a Fieldbus coding of the light paths (TLN-fc).
The Fieldbus cable is therefore led, in parallel to the LLK of the
light path, into the processing station to the external control (e. g.
of a robot).
An external control demands laser power via the connected Field-
bus cable from the laser device by means of the assigned light
path.
20-05-15-A1-CR02 2008-01 Connections 2-17

1 2 3 4 5
VMOD Diag.
Diag.Error Diag. Diag.
VHLM
VMP1 AEF ASV UCI SKO LLRS ILV INV
X22
Diag. Diag.Error
X23
X21
X24
X7
X3
X25
ASV IIOS LLKM
SUN5
7 6
X12
9
X8
X7
10
1 Ethernet interface for the opera- 5 Analog output ILV 8 Interface for connecting the
ting PC control panel (X12)
2 I/O-interface or Fieldbus interface 6 Focusing optics interface 9 Switch-on interface (X8)
3 Analog input AEF 7 Safety circuit interface 10 E-Stop interface (X7)
4 Analog output LLR
Control and part of the mains distribution Fig. 2-15
Ethernet-interface for the The control is connected to the operating PC by means of the
operating PC Ethernet interface via a RJ-45 connector. The cable which con-
nects the operating PC directly to the control can be up to 75 m
long.
E/A-interface or fieldbus in- Via the E/A-interface the laser device can be connected to the
terface external control (e.g. PLC) and be controlled from there.
Further information on this subject is to be found in chapter 4 of the
operator's manual and the interface description of the parallel I/O.
You can control the laser device as well via one of the following
Fieldbuses:
Profibus-DP
2-18 Connections 2008-01 20-05-15-A1-CR02

In this case, the board with the I/O interface is replaced by a board
of the selected Fieldbus system. Information about the pin as-
signment and the data format is to be found in the interface desc-
riptions of the selected Fieldbus system.
Analog input The optional interface „Analog input“ enables to set the laser power
as an analog value externally by voltage or current.
Analog output LLR / analog Via the interfaces of the boards laser power control (LLR) and In-
output ILV terface lamp power supply (ILV) it is possible to tap a voltage cor-
responding to the laser power potential-free.
Safety circuit interface The safety circuit interface of the laser device enables:
to integrate external safety devices into the safety circuit of the
laser device.
to connect an external laser warning lamp.
to display status signals externally.
A shutter switch releases the appertaining light path, if the safety

circuit of the shutter switch is closed.
Interface to connect the The control panel to switch the control on and off is connected to
control panel the interface X12. If you would like to operate the laser device
without control panel, it must be ensured in another way that the
signals generated by the control panel are applied to this interface.
Interface for external control If you would like to switch the functions ”Control on", "Control off"
from an external device (e. g. PLC), you will find the required con-
tacts at the interface X8 on the board SUN. Furthermore the inter-
face contains contacts to connect an external laser warning lamp
and an external monitoring lamp.
E-Stop interface Via the E-Stop interface you can:

connect further E-Stop push-buttons to the laser device.
or
integrate the laser device into a higher-ranking E-Stop circuit.
The higher-ranking E-Stop circuit can belong to a plant of which

the laser device is a part.
Note
Lay the cables to the external E-Stop devices in such a way that
they are not exposed to any danger, e.g. by crushing or being run
over.
20-05-15-A1-CR02 2008-01 Connections 2-19

4.3 Compressed air connection
If the cooling unit of a laser device shall be emptied (e.g. before

transport or longer storage), a blow-off device which is integrated
in the laser device is required for emptying the cooling lines.
The laser device must be supplied with compressed air for the
operation of the blow-off device.
Fig. 2-16
Compressed air connection with hose;
Diameter outside 8 mm
Diameter inside 6 mm
Pressure 4 ... 10 bar
Tab. 2-3
Quality of the supplied Substance of Class according to

Limit value
compressed air contents DIN ISO 8573-1
Particle size : < 1 µm
Dust 2
Quantity: < 1 mg/m³
Water 4 < 6 g/m³
Oil 3 < 1 mg/m³
Tab. 2-4
2-20 Connections 2008-01 20-05-15-A1-CR02

5. Electrical connected loads
380 V (-10 %) to 460 V (+10 %), 3AC + PE, f= 50

Hz to 60 Hz ± 3 Hz
Mains
Further data according to EN 60204-1, TN-mains
according to IEC 60364-1
cos (DPF) at nominal
0,98
power
at nominal power without cooling block: 0,89
(total power factor) with cooling block: 0,91
without cooling block: 50 A
Back-up fuse with cooling block: 63 A
gL / gG or comparable characteristics
Tab. 2-5
Power- without cooling block
Current at
Operating condition Power[kW] Power[kVA] Use
400 V [A]
1% nominal laser power (Standby) 7 9 16
Electric power at nominal laser
17 19 30 Consumption data
power at the workpiece
Maximum power consumption
20 22 34 Mains dimensioning!
(in case of service)
Tab. 2-6
Power - with cooling block
Current at
Operating condition Power [kW] Power [kVA] Use
400 V [A]
1% nominal laser power (Standby) 14 14,6 24
Electric power at nominal laser
25 26,5 40 Consumption data
power at the workpiece
Maximum power consumption
29,7 30,5 47 Mains dimensioning!
(in case of service)
Tab. 2-7
Note
The connection powers are changed after fitting optional compo-
nents retrospectively.
20-05-15-A1-CR02 2008-01 Electrical connected loads 2-21

Residual-current-operated If required, use a fault current circuit breaker (RCD type B) suitable
protective device for all currents.
Electric check Check the laser device regularly, at least each 4 years, regarding
its electric safety.
Further information on this subject is contained in chapter "Safety"
of the operator’s manual, section „Electric energy“.
If you would like to operate the laser device with mains voltages
other than mentioned above, you must use a series transformer.
Contact TRUMPF Laser, if you need further information on this
subject.
Leakage current Due to measures for radio shielding, the current in the protective
conductor has higher values than stipulated in EN 60204-1.
5.1 Electrical connection
The mains cable is inserted into the laser device through the cable
grommet and connected to the mains supply unit.
Fig. 2-17
without cooling block: 10 mm²with cooling block:

Cable cross section
16 mm²
0,5 mm² - 10 mm²Without reduction of cross sec-
connection clamps
tion: 16 mm² - 50 mm²
Tab. 2-8
2-22 Electrical connected loads 2008-01 20-05-15-A1-CR02

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. Specifications
for the connection of the lines are to be found in the interface desc-
ription „Interfaces of the laser devices“.
The laser device is only suited for connection to the electric mains
in an industrial environment.
20-05-15-A1-CR02 2008-01 Electrical connected loads 2-23

6. Cooling unit
6.1 External cooling circuit
without cooling block: +5 °C .. +20 °C

Temperature supply
with cooling block: +5 °C .. +35 °C
Pressure 6 bar
Differential pressure p 1 bar < p 6 bar with opened control
between supply and return at valves
the laser device (see "Fig. 2-19", pg. 2-25)
without cooling block: (see "Fig. 2-18",
Minimum water requirement pg. 2-25)
with cooling block: ≥ 2m³/h at 1 bar
Cooling tower water according to VDI
3803, appendix A, table 2.
Water quality In case of strongly soiled water a prefilter
115 µm µm is recommended (Filter stage
in the device 115 µm - 135 µm)
Operation with water additives (e.g. frost
protection, algae protection ...) is possible
if it is ensured that the materials used in
the cooling unit are not affected.
Water additives reduce the cooling capaci-
Water additives
ty.
Operation with water additives on possible:
at lower supply temperature
at reduced laser power
at increased flow.
Connections of supply and (see "Cooling water connections",
return pg. 2-27)
V2A, V4A,brass , (CuZn 39 PB3), PVC-U,
Material
EPDM, red brass
Tab. 2-9
Note
Note that the differential pressure refers directly to the connections
of the laser device. Connected hoses cause further pressure loss.
This one depends on the length and the diameter of the hoses.
Cooling water requirement for the tube di-

mensioning
The following characteristic lines refer to a laser device without

compressor cooling. If your laser device is equipped with an optio-
nal compressor cooling, please use the data from the table "Exter-
nal cooling circuit" (see "Tab. 2-9", pg. 2-24).
2-24 Cooling unit 2008-01 20-05-15-A1-CR02

Minimum water requirement [m³/h]
1 C
B
A
0
Supply temperature [°C]
Minimum water requirement characteristic curves Fig. 2-18
Water requirement at 1%
Characteristic of the nominal laser
line A power (Standby)
[7 kW Cooling power]
Water requirement at
Characteristic Characteristic curve for
nominal operation
line B calculating the economics
[17 kW Cooling power]
Water requirement at
maximum power con- Characteristic curve for
Characteristic
sumption (e.g. service dimensioning the pipe
line C
action) system and the chiller
[20 kWCooling power]
Tab. 2-10
Flow quantity [m³/h]
Pressure loss [bar]
Characteristic curve of pressure loss Fig. 2-19
Here the flow quantity versus the minimum pressure difference of

the laser cooler (in case of opened internal valves) is shown. Note
that the pressure difference lies at the connections of the laser
device.
20-05-15-A1-CR02 2008-01 Cooling unit 2-25

Determining the dimensio-
ning data for the external
cooling circuit
Minimum water requirement [m³/h] Flow quantity [m³/h]

4
1 C
B
A
0
Supply temperature [C°]
Example Fig. 2-20
Note
Dimension the tube system for the external cooling water so
that the required differential pressure is applied directly at the
device connections.
1. Determine the maximum possible supply temperature of the

external cooling water.
2. Read off the minimum water requirement at the corresponding
characteristic curve of water requirement (Fig. "example" left).
- In the example: Water requirement at maxium power con-
sumption at 16°C supply temperature: 2 m³/h.
3. Read off the pressure difference applicable for this flow quan-
tity between supply and return of the cooler at its characteristic
curve (Fig. "Example" right).
- In the example: 1 bar
4. TRUMPF Laser recommend a safety reserve of 0,5 bar in or-
der to compensate a slight soiling of the filter and measuring
inaccuracies on site.
- In the example: 1,5.
You must reach a minumum pressure difference > 1 bar to

ensure the function of the internal solenoid valves!
The determined values for the water requirement and the pressure
loss are dimensioned in such a way that the laser device works
reliably. If you operate the laser device with smaller values, you
reduce the control reserve of the cooler. If you operate the laser
device with smaller values, you reduce the controller reserve of the
cooler. The consequence may be that monitoring and fault mes-
sages are often displayed due to overtemperature. The operation
of the laser device is interrupted by the messages.
2-26 Cooling unit 2008-01 20-05-15-A1-CR02

6.2 Cooling water connections
6 7
5 9
8
3 4
2
1 O-rings 6 Screw-in part wrench dimension

2 Hose connection gland outer 7 Screw-in part external thread
diameter
3 Hose connection gland wrench 8 Union nut internal thread
dimension
4 Hose connection gland external 9 Union nut key dimension
thread
5 Screw-in part internal thread
Connection for cooling water supply and return Fig. 2-21
Pos. in Wrench- /
Fig. thread dimension
outer diameter 2 33mm (1¼")
Hose connection
gland wrench dimension 3 46 mm
external thread* 4 RP-DIN 2999 (1¼ ") *
internal thread * 5 IRP-DIN 2999 (1¼ ")
Screw- in part wrench dimension 6 49 mm
external thread* 7 ISO 228-G 2 "
internal thread * 8 ISO 228-G 2 " *
Union nut
wrench dimension 9 70 mm
Tab. 2-11
*sealed by means of O-ring

A hose connection gland (Mat.-No. 1433033), on which the cooling
water hose is mounted, is screwed into the screw-in part.
A union nut is tightened at the screw-in part for the connection of

the cooling water hose.
20-05-15-A1-CR02 2008-01 Cooling unit 2-27

6.3 Data for chillers
If the operate the laser device together with a chiller, the chiller
must meet at least the requirements indicated in the following ta-
ble.
The use of a chiller is not required when using an optional internal
cooling block.
Cooling power ≥ 18 kW (Nominal power after degradation)

Minimum water
(see "Fig. 2-18", pg. 2-25)
circulation quantity
Pressure
(see "Fig. 2-19", pg. 2-25)*
difference supply-return
Recommended for pressures < 6 bar
Overflow valve
Required for pressures > 6 bar
Tab. 2-12
*) Recommendation: value from characteristic line of pressure loss

+ pressure loss for tube and hose connection.
The tube and hose system of the connections is to be dimensioned

in such a way that a pressure loss of 1 bar is not exceeded for the
required water quantity. If this is the case anyway, the delivery
height of the pump must be adapted correspondingly.
2-28 Cooling unit 2008-01 20-05-15-A1-CR02

6.4 Installation examples
1 House water circuit
Fig. 2-22
House water circuit Connected to a domestic cooling plant or a cooling tower.
1 Standard chiller 2 House water circuit
Fig. 2-23
House water circuit Connected to a standard chiller (1) with cooling against air.
The standard chiller can be supplied by TRUMPF Laser.
20-05-15-A1-CR02 2008-01 Cooling unit 2-29

6.5 Laser cooling circuit
Cooling means Deionized water

Quantity ca. 95 l
Conductivity 1 - 5 µS
Specifications on the laser cooling circuit Tab. 2-13
Conductivity Low conductivity of the cooling water increases the utilization peri-
od of the deionizing filter.
The conductivity of the cooling water in the laser cooling circuit is
controlled to a value in the range 2,5 µS .. 3,5 µS. If the value is
more than 1µS below /or 1,5 µS above this range, a monitoring or
a fault message is indicated.
If the conductivity of the cooling water in the laser cooling circuit
increases over 5 S or falls below 5 S, a monitoring message is
indicated. Then you can still operate the laser device.
If the conductivity of the cooling water in the laser cooling circuit
increases over 8 S, then a fault message is indicated. Then you
only can operate the laser device again, if you have replaced the
cooling water and the deionizing filter of the laser cooling circuit.
The replacement of the deionizing filter and the cooling water is
described in chapter "Maintenance".
If the conductivity falls below 0,5 µS, then a fault message is indi-
cated as well. The laser device can no longer be operated. In this
case contact the TRUMPF Laser service department.
Cooling of externally-bought DI water from the cooling circuit of the laser can result in cor-
components rosion in components containing materials not resistant to DI
water. Corrosion products that enter the laser device via the
cooling circuit can cause damage in the laser.
TRUMPF Laser shall only be liable in accordance with legal
regulations for damage caused by defects in devices or com-
ponents delivered by TRUMPF Laser. TRUMPF Laser cannot
be held liable for damage caused by foreign products.
2-30 Cooling unit 2008-01 20-05-15-A1-CR02

7. Ambient conditions
Operation +10 °C .. +40 °C

Temperature
Storage +5 °C .. +40 °C
max. 40 % at 40 °C,
Relative humidity
higher humidity possible at lower temperature.
Laser device IP 54 in case of closed front doors
Protection class See specifications of the manufac-
Operating-PC
turers
Tab. 2-14
IP 54 Protection class IP 54 only takes effect, if all hoods, doors and

covers are closed. In case of strong environmental stress by dust
or aerosols, TRUMPF Laser recommends creating a housing -
which protects the laser even in the opened state against environ-
mental influences - around the laser device.
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 Fig. 2-24
In order to determine the ambient conditions, the ambient tempe-

rature and the air humidity in the environment of the laser device
must be measured.
If the required ambient conditions are not kept, a corresponding
environment must be created for the laser device artificially (cabin,
air conditioning).
20-05-15-A1-CR02 2008-01 Ambient conditions 2-31

8. Emissions
Sound level Laser device < 60 dB(A) according to EN ISO 3744

Processing spot Depending on the application
Tab. 2-15
9. Telepresence
TRUMPF offers with the Telepresence worldwide a unique service.

Up to 1000 measuring values are steadily recorded in the scope of
the Telepresence. Via a modem it is possible to call up the operat-
ing and check data as well as all measuring values at any time and
to transmit them to each TRUMPF service office.
On demand of the customer, the TRUMPF service specialists carry
out a preventive maintenance at the laser devices by means of the
Telepresence. Furthermore faults can be diagnosed quickly, and
immediately be evaluated and remedied. In large part on-site ac-
tions are not required and the standstill periods on the customers’
premises are reduced significantly.
For the operation of the option Telepresence a telephone connec-

tion with the following characteristics is required:
Signal shape: analog
Connection: RJ 12 or TAE
The access to the option Telepresence can optionally be effected

via:
an analog modem
a Remote Access Service (RAS)
a Virtual Private Network (VPN).
Further information on the Telepresence: (see chapter "Descrip-

tion").
2-32 Emissions 2008-01 20-05-15-A1-CR02

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

situations when handling the laser device. The situations are:
Switching the laser device on and off.
Operating the laser device
Maintenance of the laser device.
10.1 Position for switching on and off
Fig. 2-25
Note
Position the laser device in such a way the main switch can be
reached easily.
10.2 Position for operating the laser device
If the laser device is switched on, all operating processes can be

carried out from the operating PC.
Fig. 2-26
20-05-15-A1-CR02 2008-01 Position of the user 2-33

10.3 Position for setting the focusing optics
The position or the setting work at the focussing optics is at the

processing stations.
Fig. 2-27
10.4 Position for maintenance work
1 Maintenance of the focusing 4 Replacing the pump module 6 Works at the connections
optics
2 Replacing the laser light cable 5 Maintenance of the cooler 7 Replacing the fuse
3 Maintenance of the air cleaner
Fig. 2-28
2-34 Position of the user 2008-01 20-05-15-A1-CR02

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

The shipping agent.
The insurance agency which insured the transport.
The dispatch department of TRUMPF Laser.
11.2 Commissioning
Only TRUMPF Laser staff or persons especially trained for this

purpose are permitted to put the laser device into operation.
DI-water Keep ready a sufficient quantity of deionized water for the commis-
sioning(see "Laser cooling circuit", pg. 2-30).
Condensate During work with the laser a small quantity of condensed water
develops in the air cleaner.
Hold a vessel ready for collecting the condensate.
Check cooling block The laser device can be equipped with an optional cooling block.
A check of the cooling block is required:

If the site of the device is changed after the first commissio-
ning.
After a standstill period of more than two years.
Information on this subject is to be found in the operator's manual

of the cooling block.
Shipping brace of the The compressor of the air cleaner is locked with a shipping brace
compressor on delivery.
ImportantThe shipping brace of the compressor must absolutely
be removed from before commissioning (see "Removing the ship-
ping brace of the compressor", pg. 2-36).
The shipping brace must be mounted before a transport.
20-05-15-A1-CR02 2008-01 First measures to be taken after receipt of the laser

device
2-35
Removing the shipping brace of the
compressor
Fig. 2-29
1. Open the air cleaner at the rear side of the laser device.
2. Unscrew the screw of the two red shipping braces downward
(arrows, above).
3. Secure the shipping braces with the screws on the right and
left of the frame (arrows, below).
2-36 First measures to be taken after receipt of the laser

device
2008-01 20-05-15-A1-CR02
Adjusting the level difference
1 Head 2 Counter nut
Adjustment thread of an adjustable leg Fig. 2-30
1. Loosen counter nut (2).

2. Set the adjustable leg at the head (1) to the correct position.
3. Tighten the counter nut.
All adjustable legs must be placed on the floor with about the same
force.
20-05-15-A1-CR02 2008-01 First measures to be taken after receipt of the laser

device
2-37
12. Transport
Appropriate transport means for the movement of the laser device

within in a building or on the premises are:
Pallet jack
Fork-lift truck
Crane with lifting gear.
Appropriate packaging is required for the long-distance transport

with vehicles (see "Packing the laser device", pg. 2-44).
12.1 Transport by means of pallet jack
Conditions
To move the laser device at the installation site:

The laser device must be switched off.
Laser light cables and supply lines must be laid in such a way
that sufficient motion reserve is available.
It must be ensured that laser light cables and supply lines are
not damaged.
To change the installation site of the laser device:

All lines which lead from other devices to the laser device (e. g.
from external controls) must be disconnected.
The mains cable must be separated from the electrical mains.
The laser light cable must be disconnected from the laser de-
vice.
The cooling unit must be emptied completely, if during trans-
port or during the storage of the laser device there can be
temperatures below 0 °C.
– For emptying the cooling unit a compressed air connection
is required.
– A detailed description for the emptying of the laser cooler
is to be found in chapter "Maintenance".
Note
Two pallet jacks are required for the transport of the laser device.
To actuate the pallet jacks and to move the laser device two per-
sons are required.
Minimum loading capacity per pallet jack

without cooling block 10 kN (1000 kg)
with cooling block 11 kN (1100 kg)
Tab. 2-16
2-38 Transport 2008-01 20-05-15-A1-CR02

Parts of the body can get between pallet jack and the subject
to be transported or between subject to be transported and
the ground!
Parts of the body can be broken or crushed.
Caution
Observe the safety regulations when operating the pallet
jack.
Placing the pallet jack in position Fig. 2-31
1. Placing the pallet jack in position
Wrong positioning of the pallet jack may lead to high materi-

al damage.
Introduce the pallet jack until its front wheels are positioned in
the opening.
Warning
Lift the fork carefully.
Inserting the pallet jack Fig. 2-32
2. Inserting the pallet jack
20-05-15-A1-CR02 2008-01 Transport 2-39

12.2 Transport by fork lift truck
Conditions
Before transport:
vice.
is required.
Minimum loading capacity of the fork-lift truck

Tab. 2-17
Fig. 2-33
2-40 Transport 2008-01 20-05-15-A1-CR02

Parts of the body may get between fork lift truck and the item
to be transported.
Parts of the body can be broken or crushed.
There must not be any persons in the danger zone of the fork
Caution
lift truck.
The laser device may only be transported by instructed per-
sons.
Observe the safety regulation of the transport means.
1. Put a padding mat over the laser device so that the front side is
protected.
2. Set the lifting fork as wide as possible. Then the laser device is
positioned more stably on the lifting fork.
Note
The laser device may not be inclined more than about 10°.
3. Lift the laser device carefully by means of the fork-lift truck.
4. If you would like to transport the laser device over a longer
distance or over an uneven surface: Save the laser device
against slipping by means of a belt.
5. When moving, avoid:
– Abrupt start and stop.
– Quick cornering.
6. Place the laser device carefully.
20-05-15-A1-CR02 2008-01 Transport 2-41

12.3 Transport by means of a crane
Conditions
Before transport:
vice.
is required.
Means, Tools, Materials

Bars:
– 2 pieces
– steel, circular cross section, Ø ca. 40 mm,
– Length: > 2300 mm
Lifting belts with loops at each end:
– 4 pieces
– resistance to tearing > 10 kN (1000 kg)
– Length: > 2800 mm
Expander device:
– to keep the lifting belts apart
The suspended load may swing. Ropes, belts or chains may

tear or get loose!
Loads falling down may cause death or serious damage to
material property.
Danger
Oscillating loads may cause injuries and damages to materi-
al property.
Only use undamaged ropes, belts or chains that have the
necessary resistance to tearing.
Secure ropes, belts or chains against sliding down.
Only those persons are allowed to stay in the danger area of
the crane whose presence is absolutely necessary.
Persons staying in the danger area of the crane must wear a
hard hat.
Observe the safety regulations for the crane!
Minimum carrying force of the crane:

Tab. 2-18
2-42 Transport 2008-01 20-05-15-A1-CR02

1 Padding mat 4 Protection against slipping
2 Metal bars 5 Spacer
3 Lifting belts 6 Crane hook
Transport by means of a crane Fig. 2-34
1. Put the padding mat (1) over the laser device so that the front
side and the rear side are protected where the lifting gear is
placed.
2. Put metal bars (2x) (2) through the base of the laser device.
They should protrude in the back and in the front with about
the same length.
3. Fasten the lifting belts (4x) (3) with the same length at the me-
tal rods.
4. Secure the lifting belts at the metal bars against slipping (4).
5. Fit a spacer (5) between the lifting belts. The spacers prevent
that the hoods of the laser devices are twisted.
6. Hook in the crane hook (6).
Fig. 2-35
7. Lift the laser device carefully.
8. Move the crane in such a way that the laser device does not
oscillate.
9. Place the laser device carefully.
20-05-15-A1-CR02 2008-01 Transport 2-43

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

2. Emptying the cooling unit of the laser device (see chapter
"Maintenance").
3. Disconnect all electric connections from the laser device.
4. Depressurize all pressure pipes leading to the laser device.
Fig. 2-36
5. Disconnect the compressed air supply line.

6. Disconnect the laser light cable (see chapter "Maintenance").
Fig. 2-37
7. Remove the laser warning lamp and pack it separately.

8. Disconnect the control panel from the cable and pack separa-
tely.
2-44 Transport 2008-01 20-05-15-A1-CR02

Packaging
2 3 4
1 5
3 6
6
1 Pallet 3 Hard foam panel 5 Blister foil

2 Plastic foil vapor coated with 4 Plywood panel 6 Wooden frame
aluminum
Components of the inner packing Fig. 2-38
9. Attach the inner packing of the laser device as described in

section Fig. 2-37 and Tab. 2-14.
20-05-15-A1-CR02 2008-01 Transport 2-45

Pos. Designation Additional information
Support for fork lift Dimensi- 3200 x 1500
1 Pallet
transport ons [mm] incl. 3 skids, 1500 x 10 x 10
2 pieces: Sheet for support and hood for laser
Plastic foil vapor Material
Protection from moi- device
2 coated with
sture to allow the entire laser device fastened to the
aluminum Dimensions
pallet to be sealed in the film.
PE foam sheet Recommendation: Nopaplank,
Material
thickness: 50 mm, 65 kg/m³
Hard foam panel
Dimensions
3200 x 1500 x 50
[mm]
3 Hard foam panel Protection of the Dimensi-

3200 x1 500 x 50 (2 x)
cover from scratches ons [mm]
Dimensi-
1500 x 50 x 50 (2 x)
Protection of the base ons [mm]
from scratches Dimensions
3200 x 50 x 50 (2 x)
[mm]
Protection of the hard Dimensions
4 Plywood panel 3200 x 1500 x 13
foam panel [mm]
Protection from
5 Blister foil Dimensions to allow the entire laser device to be covered
scratches
Fixing of the laser Dimensi- 3200 × 50 × 50 (2×)
device against sliding ons [mm] 1500 x 50 x 50 (2 x)
Fixing of the foamed Dimensi-
3200 x 50 x 20 (2 x)
6 Wooden frame sheet against sliding ons [mm]
Do not attach wooden beams until the laser device is on the pal-
let.
This is the only way of ensuring that the wooden beams fix the
laser device in the best possible way.
Explanations to the inner packing Tab. 2-19
1 Hard foam panel 2 Stretch film
Inner packing Fig. 2-39
10. Enwrapping the laser device with stretch film. Do not use any
tensioning belts!
2-46 Transport 2008-01 20-05-15-A1-CR02

1
2
3
4
5 5
1 Plastic foil vapor coated with 3 Corrugated sheet 5 Hard foam panel
aluminum
2 Crossbeam 4 Paper 6 Tightening straps
Outer packing Fig. 2-40
11. Completely seal the laser device in plastic foil vapor coated
with aluminum (see "Fig. 2-40", pg. 2-47)(1).
20-05-15-A1-CR02 2008-01 Transport 2-47

Tip
A service enterprise may provide you with a sealing device for
sealing the film, if required.
12. Fill out all spaces in between with hard foam panels.
13. Enclose enough desiccant (e.g. silica gel) with the laser device
and the accessories.
14. Attach the wooden walls (see Fig. 2-40).
15. Attach tightening straps
– Width: ca. 25 mm
– tensile strength ca. 9,3 kN (950 kp)
– number: 4
16. Label the packaging:
"Transport in upright position only!".
2-48 Transport 2008-01 20-05-15-A1-CR02

Chapter 3
Description
1. Overview ......................................................................... 3-3
2. Laser ............................................................................... 3-4

2.1 Design.............................................................................. 3-4
2.2 Specifications................................................................... 3-5
3. Optical arrangement...................................................... 3-6

3.1 Components of the optical arrangement ......................... 3-8
Central shutter (VZ) .................................................... 3-8
Shutter (V1, V2, ...) ..................................................... 3-9
Switch (W1, W2, ...) .................................................... 3-9
Shutter switch (VW1, VW2, ...) ................................. 3-10
Shutter switch with pilot laser ................................... 3-12
Physical splitter with adjustable splitter ratio ............ 3-13
Deflection (U1, U2, ...) .............................................. 3-13
Deflection 2 x 45° ..................................................... 3-14
Power and energy measuring sensor (LEM)............ 3-14
4. Incoupling optics ......................................................... 3-17
20-05-15-A1-CR02 2008-01 Description 3-1

5. Laser light cable (LLK-D) ............................................ 3-18
6. Focusing optics ........................................................... 3-20
7. Control .......................................................................... 3-22
8. The mains distribution ................................................ 3-24
9. Laser cooler ................................................................. 3-26
10. Cooling block (Option) ................................................ 3-28
11. Cabinet cooler.............................................................. 3-30
12. Air cleaner .................................................................... 3-32
13. Diode current supplies................................................ 3-34
14. Blow-out device ........................................................... 3-35
15. Operating-PC................................................................ 3-36
16. Control panel................................................................ 3-38
17. WinLas program .......................................................... 3-39

17.1 Functions of the WinLas program.................................. 3-39
17.2 Main screen ................................................................... 3-40
Menu......................................................................... 3-41
Soft keys ................................................................... 3-41
Icon bar..................................................................... 3-42
Power display ........................................................... 3-43
Selecting light path ................................................... 3-44
17.3 Dialogs ........................................................................... 3-46
Dialog box “Select operating mode” ......................... 3-47
Dialog “Light path overview“ ..................................... 3-48
17.4 User levels ..................................................................... 3-50
Selecting user level................................................... 3-51
18. Telepresence................................................................ 3-52

18.1 Direct connection over an analog modem ..................... 3-52
18.2 Connection via RAS....................................................... 3-53
18.3 Connection via VPN....................................................... 3-53
18.4 User configuration of the operating-PC ......................... 3-54
18.5 Firewall configuration..................................................... 3-54
3-2 Description 2008-01 20-05-15-A1-CR02

1. Overview
1 2 3 4
7
6
16 9
10
E 11
12
15 14 13
1 Operating-PC 7 Laser cooler 12 The mains distribution

2 Control panel 8 Control 13 Air cleaner
3 Optical arrangement 9 Incoupling optics 14 Cabinet cooler
4 Laser 10 Laser light cable (LLK) 15 Cooling block (Option)
5 Diode current supply 11 Focusing optics 16 Blow-out device
6 Cooling control (CLC)
Laser device, components Fig. 3-1
20-05-15-A1-CR02 2008-01 Overview 3-3

2. Laser
2.1 Design
1
2
4
5
1 Pump units 4 Folding mirrors

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

Pump units .
Cavities with laser disk.
Resonator, comprising end mirrors and output coupling mir-
rors.
The output coupling mirror is partially transmitting for laser light.

The cavities and the pump units are cooled with deionized water.
3-4 Laser 2008-01 20-05-15-A1-CR02

2.2 Specifications
The following values of laser power and beam parameter product

are available at the working station.
Wavelength of the laser light 1030 nm

Minimum laser power 40 W
Maximum laser power 4000 W
Beam parameter product 8 mm·mrad
Specifications of the laser Tab. 3-1
A characteristic curve containing the measured values of your laser

device can be found in the acceptance certificate.
20-05-15-A1-CR02 2008-01 Laser 3-5

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

the laser light within the laser device until the beam enters the in-
coupling optics. The laser light cable is connected to the incoupling
optics.
The components of the optical arrangement are grouped and ar-
ranged according to the respective machining task.
The components of the optical arrangement are mostly accommo-
dated in transparent plastic cases. Between the components there
are metal beam guard elements of circular cross section.
The following picture shows an example of an optical arrangement.
The picture shows the main components available for optical ar-
rangements. The meaning and function of the components are
explained below.
A representation of your optical arrangement is to be found in the
documentation delivered together with your laser device. To un-
derstand the functions of your optical arrangement: (see "Compo-
nents of the optical arrangement", pg. 3-8).
3-6 Optical arrangement 2008-01 20-05-15-A1-CR02

1
4
3 100
3
3
100
4 5
14
LASER
7
VW 3
A43
13 12 11 10 9 8
1 Laser light cable (LLK) (6x) 6 Deflection 90° 11 Central shutter

2 Incoupling optics 7 Holder for plasma sensor 12 Shutter switches
3 Beam shielding 8 LEM* 13 Deflection for absorber
4 Deflection for absorber 9 Deflection 90° 14 Absorber
5 Absorber for central shutter 10 Deflection for LEM
Optical arrangement Example Fig. 3-4
*LEM: Power and energy measuring sensor

The laser light is fed in at the point to which the arrow designated
“LASER” is pointing.
The central shutter VZ can block or enable the laser light for all
light paths.
The positions of the shutter switches VW determine to which light

path the laser light is guided.
Further information on the functions of the optical arrangement

components is written below.
20-05-15-A1-CR02 2008-01 Optical arrangement 3-7

3.1 Components of the optical arrange-
ment
Central shutter (VZ)
1 Laser beam blocked 3 Absorber 5 Mirror moved out of beam gui-

deway
2 Mirror in beam guideway 4 Laser beam enabled
Fig. 3-5
By means of the central shutter is possible to block (chart A) or to

release (chart B) the emission of the laser beam.
If the laser beam is released, it passes through the central shutter
as shown in chart B. If the laser beam is blocked, the central shut-
ter guides it into the absorber (3), where it is transformed into heat.
In the currentless state the central shutter is blocked.
The central shutter has 2 functions:
Working function Working function In the working function the central shutter is
opened and closed by user commands and laser programs as long
as the safety circuit is closed.
Safety function If the safety function is interrupted, the central shutter is closed
immediately. This happens as well when the there is the command
for opening by the user or by the running laser program.
Further information on the operating mode and the wiring of the
safety circuit is to be found in the interface description Safety circu-
it ASV.

Shutter (V1, V2, ...)
The shutter can enable or lock a light path. When the shutter
enables the light path, the laser beam passes through it as shown
in picture B (see "Fig. 3-5", pg. 3-8). When the shutter closes the
light path, the laser beam will be guided into an absorber (picture
A).
The shutter is opened or closed by operator-originated commands
or laser programs.
When the shutter is controlled by an ASV or ASV2 board, it can be
integrated into a safety circuit. In this case it has not only an ope-
rating function, but also a safety function. What has been said
regarding the safety function for the central shutter will then also
apply analogously to the light path in which the shutter is located.
Switch (W1, W2, ...)
1 Mirror moved out of beam guideway 3 Mirror in beam guideway

2 Laser beam passes through in a straight line 4 Laser beam is deflected by 90°
Fig. 3-6
The laser beam can be guided optionally into one of two directions
by means of a beam switch.
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 guide-
way, the laser beam passes through the beam switch in a straight
line (picture A).
The beam switch can be controlled by user commands or by laser
programs.

Shutter switch (VW1, VW2, ...)
A VW1 and VW2 closed B VW1 open C VW2 open
Fig. 3-7

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 ac-
tivation of the shutter switch by an ASV or ASV2 board. The shut-
ter switch is integrated into a safety circuit via the ASV or ASV2
board.
Thus, the shutter switch has two functions:
Operating function In the operating function the shutter switch is controlled by opera-
tor-originated commands or laser programs as long as the safety
circuit 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.
3-7", pg. 3-10) (picture A) . This also happens when a different
command comes from the operator or from the running laser pro-
gram.
Information about functioning and wiring of the safety circuit is to
be found in the interface description safety circuit ASV.
The number of shutter switches in an optical arrangement is usu-
ally identical to the number of light paths. The shutter switches are
arranged in series. They are activated in such a way that at most
one shutter switch is open (mirror in the beam guideway, (see
"Shutter switch (VW1, VW2, ...)", pg. 3-10) (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.

Shutter switch with pilot laser
1 pilot laser 3 Pilot laser beam

2 Shutter switch mirror
Fig. 3-8
The casing of the shutter switch with pilot laser houses a semi-
conductor laser is (1). The semiconductor laser works as pilot laser
of the light path to which shutter switch is assigned. In contrast, the
central pilot laser can be used in all light paths.
Advantage The pilot laser in the shutter switch can be used while the working
laser light is being guided to a different light path. This makes it
possible to use the pilot laser at processing point, while workpieces
are being machined at a different point.
Shutter switch functions The basic shutter switch functions (work and safety function) are
identical, as are those of the shutter switch without pilot laser (see
"Fig. 3-7", pg. 3-10).
Switching the pilot laser on The pilot laser can be switched on as soon as the shutter switch
mirror has been swiveled out of the beam guideway (shutter closed
(see "Fig. 3-8", pg. 3-12)).
Switching on the workstation with the user interface is described in
chapter "Operation" .
Laser classes The pilot laser has been classified as a Class 3R component.
This must be taken into account when it is operated, for example
by the service, after removal from the unit.
In standard operation, the pilot laser light emitted from the focu-
sing optics outlet corresponds to class 2.

Physical splitter with adjustable splitter ratio
Fig. 3-9
The physical splitter with adjustable splitter ratio contains a se-

mi-transparent mirror with variable transparency over the angle of
rotation. Accordingly, the splitter ratio depends on the angular posi-
tion of the mirror.
The proportion a of the deflected beam can be set to a value in the
range from 20% to 80% on an actuator (arrow).
Deflection (U1, U2, ...)
Fig. 3-10
The deflection deflects the laser beam by 90° to the right or left.

Deflection 2 x 45°
Fig. 3-11
The deflector 2 x 45 deflects the laser beam via 2 mirrors by 90°. A

LEM can be attached to this deflector.
Power and energy measuring sensor (LEM)
Fig. 3-12
The LEM produces an electric signal which corresponds to the

momentary power of the laser. The power of the laser or the ener-
gy of laser pulses can be determined by this.
The LEM is attached to the end mirror of the laser or to a deflection
of the optical arrangement. Through the end mirror, or through the
mirror of the deflection, a small part of the laser power is coupled
out and fed into the LEM.
If the laser device is provided with a laser power control, the LEM
measures the actual value of the laser power.

3.2 Selecting light path
The positions of the mirrors in the controllable components of the

optical arrangement (beam switches, shutter switches, shutters)
determine the light path.
Light path determined by VW2 Fig. 3-13
In this picture the mirror of shutter switch VW2 has been swiveled
into the beam guideway. At this point, the laser is deflected by 90°
and coupled into the laser light cable connected to this light path.
Light path determined by VW1 Fig. 3-14
In this picture the mirror of shutter switch VW1 has been swiveled
into the beam guideway. At this point, the laser is deflected by 90°
and coupled into the laser light cable connected to this light path.

Light path in the absorber Fig. 3-15
In this picture 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.
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 can be selected:

via the software interface of the laser device (see chapter
"Description").
in laser programs (see chapter "Description").

4. Incoupling optics
Fig. 3-16
Fig. 3-17
The incoupling optics contains a lens which focuses the laser

beam to the beginning of the light guide in the laser light cable.
20-05-15-A1-CR02 2008-01 Incoupling optics 3-17

5. Laser light cable (LLK-D)
Fig. 3-18
Purpose The laser light cable is a flexible transmission medium for laser
beams. It allows spatial separation between laser and machining
station.
Design In the interior of the laser light cable there is light guide, which
guides the laser beam from the laser device to the focusing optics.
The light guide is surrounded by a plastic tube and a steel casing.
The steel casing protects the light guide from mechanical stress. It
limits the bending radius of the laser light cable.
The steel casing is surrounded by an external plastic tube which
protects the laser light cable against environmental effects.
A safety device integrated into the laser light cable switches the
laser automatically off, when the optical wave guide is damaged or
the laser light cable at the laser or at the focusing optics is pulled
out.
Technical data Standard lengths 2 m, 4 m, 6 m, 8 m, 10 m, 15 m, 20 m, 30 m,

40 m, 50 m lengths up to 100 m on demand.
Min. permissible
200 mm
bending radius
Cable core diameter 12,5 mm
Fiber core diameter 200 µm, 300 µm, 600 µm
Tab. 3-2
3-18 Laser light cable (LLK-D) 2008-01 20-05-15-A1-CR02

1 Protective glass 4 Cooling water connections plug
cooling
2 Optical plug, laser side 5 Cables
3 Electrical plug, monitoring 6 Optical plug, processing side
Laser light cable, components Fig. 3-19
Monitoring The laser light cable is monitored on the whole length. The laser
device switches off immediately and no more laser light may be
emitted if a fault occurs in the laser light cable.
The fit of the two optical plugs is monitored as well. If an optical
plug is loosened, the laser device immediately switches off.
The integrated monitoring of the laser light cable is connected with
the safety circuit of the laser device by means of the electrical plug.
Laying the LLK Outside the laser cabin, laser light cables must be installed per-
manently.
To do so, use:
Cable clamps
Cable ducts
Other appropriate auxiliaries for fastening cables.
Inside laser cabins which are monitored by a safety circuit, laser

light cables can be laid freely and loosely.
20-05-15-A1-CR02 2008-01 Laser light cable (LLK-D) 3-19

6. Focusing optics
Fig. 3-20
The focusing optics focuses the laser light onto the processing
point. The high power density required for the material processing
is generated thereby.
Focusing optics are composed of modules according to the requi-
rements of the respective task.
Further information is to be found in the operating manual of your
focusing optics.
3-20 Focusing optics 2008-01 20-05-15-A1-CR02

1
4
8
7
6
1 Receptacle for LLK plug 5 Splitter and deflection

2 Collimation 6 Lens with lens protection
3 Set ring for defocusing 7 Observation optics
4 Counterring 8 Eyepiece
Focusing optics (example of welding optics) Fig. 3-21
20-05-15-A1-CR02 2008-01 Focusing optics 3-21

7. Control
Fig. 3-22
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 informa-
tion about this is to be found in chapter 2 of this manual and in the
interface descriptions.
Controlling The most important functions are:

Switching the laser on and off
Controlling the optical arrangement
Controlling the laser power
Communication with external units (e.g. PLC).
Monitoring The control unit also monitors the following operational values:
Laser power
Temperature of the coolants
Temperatures within the area of the laser and of the optical
arrangement
Condition of the laser light cable
Safety contacts at the processing points.
Messages If the operational value is outside the admissible range, the control
generates a monitoring message or a fault message.
The message is indicated on the screen of the operating PC. In
case of a fault, the control prevents the operation of the laser until
the cause for the fault is eliminated.
3-22 Control 2008-01 20-05-15-A1-CR02

Configuration
VMOD Diag.Error Diag. Diag.

Diag.
VMP1 VHLM AEF ASV 2 UCI SKO LLR5 ILV INV

X22
Diag. Diag.Error
X23
X21
X24
X7
X3
X25
ASV 2 IIOS LLKM
1 Host processor 6 UCI board 11 Board for operating and safety

shutter (ASV2)
2 Interface circuit board 7 Scattered light monitoring optics 12 Interface Intelligent Optics (IIO)
3 VHLM board 8 LLR5 board 13 Slot for other boards IIO and
ASV2
4 Analog interface board 9 Interface diode power supply 14 Monitoring LLK and TKO
5 Board for operating and safety 10 Interface, mains distribution 15 24 volt connections
shutter (ASV2)
Control unit of the laser device Fig. 3-23
The control system is composed of individual electronic compo-

nents. The component parts of the control unit can differ from the
figure.
20-05-15-A1-CR02 2008-01 Control 3-23

8. The mains distribution
Fig. 3-24
The mains distribution distributes the electrical energy to the indi-

vidual consuming devices.
The board ”Signal conversion Mains Distribution" (SUN 5) of the

mains distribution converts the signal levels and provides inter-
faces for:
EMERGENCY STOP circuit
Control panel
User interface.
3-24 The mains distribution 2008-01 20-05-15-A1-CR02

1 2 3 4 5 6
8
9
10
11
12
20 19 18 17 16 15 14 13
1 Automatic circuit breakers 8 Power supply camera optical 15 Terminal strip

arrangement
2 Fuses 9 Safety relay hood switch 16 Transformer for service socket
3 Line filter 10 EMERGENCY STOP relays 17 Capacitor for pos. 14
4 Main switch 11 Control contactors 18 Contactors
5 24 V power pack start-up circuit 12 Microfuses 19 Service socket
6 Automatic circuit breakers 13 Interfaces 20 Terminal strip
7 24 V power pack control voltage 14 Status indicators
The mains distribution Fig. 3-25
Detailed information about the mains distribution can be found in

the circuit documents.
20-05-15-A1-CR02 2008-01 The mains distribution 3-25

9. Laser cooler
1
2
1 Laser cooler 2 Cooling control (CLC)
Fig. 3-26
The laser cooler dissipates the heat arising in the laser through a
heat exchanger to an external cooling circuit. The temperature of
the laser circuit is regulated to a constant value.
According to the situation at the installation site, it may be required

to operate the laser device with an integrated cooling block or an
external chiller. The technical data for an external chiller are to be
found in the chapter "Installation conditions, transport". Further
information on the cooling block:(see "Cooling block (Option) ", pg.
3-28).
3-26 Laser cooler 2008-01 20-05-15-A1-CR02

3 4 5
8 7
1 Tank 4 Stop valve in the return 7 Pump

2 Backflushable entry filter 5 Heat exchanger 8 Deionizing filter
3 Stop valve in the supply 6 Fine filter
Laser cooler Fig. 3-27
The laser is cooled with deionized water. The pump delivers the
water from the tank via the supply distributor to the cooled compo-
nents:
Cavities and other cooled components of the laser.
Absorber in the optical arrangement.
Focusing optics.
Cabinet cooler.
Diode current supply.
The water absorbs the heat in the components and flows through
the return collectors into the heat changer where the heat is dissi-
pated to the external cooling circuit. From the heat exchanger the
water flows back to the tank.
20-05-15-A1-CR02 2008-01 Laser cooler 3-27

10. Cooling block (Option)
Fig. 3-30
The cooling block enables the operation of the laser device even if
the temperature of the house water circuit is above the permissible
value of 19 °C. By the additional cooling power of the cooling
block, a supply temperature of the housewater circuit of up to
35 °C is possible.
If the temperature of the housewater circuit is permanently under
19 °C, the cooling block can be switched off in order to save ener-
gy.Contact the service TRUMPF Laser, if you need further informa-
tion.
3-28 Cooling block (Option) 2008-01 20-05-15-A1-CR02

1
2 3
1 Condenser 3 Compressor
2 Vaporizer 4 Control of the cooling block
Fig. 3-31
20-05-15-A1-CR02 2008-01 Cooling block (Option) 3-29

11. Cabinet cooler
Fig. 3-32
The cabinet cooler dissipates the heat arising in the interior of the
laser through a heat exchanger to the laser cooling circuit. In this
way, the temperature in the cabinet is regulated to a constant
value, independent from the ambient temperature.
3-30 Cabinet cooler 2008-01 20-05-15-A1-CR02

1
2 3
1 Fan 3 Connections of the laser cooling

circuit
2 Heat exchanger
Components of the cabinet cooler Fig. 3-33
20-05-15-A1-CR02 2008-01 Cabinet cooler 3-31

12. Air cleaner
Fig. 3-34
Cavities and pump modules must constantly be supplied with dry

and cleaned air. An air cleaner is installed in the laser device for
this reason.
3-32 Air cleaner 2008-01 20-05-15-A1-CR02

1 intake filter 6 Frequency converter 11 water separator + preliminary
filter
2 Air entry 7 Control board 12 Heat exchanger
3 Clean air connection laser 8 active carbon filter 13 Overflow valve
4 Replacement filter cartridge for 9 Condensed water outlet 14 Compressor
active carbon filter
5 Dryer unit 10 submicro filter
Air cleaner, controller swivelled out Fig. 3-35
The ambient air comes into the laser device through the intake
filter in the right cabinet door on the rear. The compressor feeds
the air through the cleaning system. The air is cleaned until clean
air with a relative humidity < 30 % is obtained.
20-05-15-A1-CR02 2008-01 Air cleaner 3-33

13. Diode current supplies
Fig. 3-36
The 4 diode power supplies provide the pump units of the laser
with electric energy.
The diode power supplies provide the current in such a way that
the determined temporal course of the laser power is reached.
The control monitors steadily the diode power supplies. Operatio-
nal values and states of the diode power supplies can be displayed
on the user interface.
3-34 Diode current supplies 2008-01 20-05-15-A1-CR02

14. Blow-out device
Fig. 3-37
1
2
1
5
4
1 Pressure indicator 4 Compressed air inlet

2 Adapter for different hose 5 Compressed air outlet
diameters
3 On / Off switch
Fig. 3-38
The blow-out device serves for dewatering the cooling circuits du-
ring maintenance work.
For further information about dewatering the cooling circuits please
refer to chapter "Maintenance", sections "Replacing pump modu-
les" and “Draining off and filling the cooling unit”.
20-05-15-A1-CR02 2008-01 Blow-out device 3-35

15. Operating-PC
Fig. 3-39
Usually your laser device is operated by means of an operating PC

which is placed next to the laser device. On the operating PC, the
WinLas program is installed for controlling the laser device.
If you use an industrial PC, the WinLas program can be operated
fully by using a touch screen. This requires neither a mouse nor a
keyboard.
Touch screen Touch screen means more or less: ”a screen that you can touch".
The screen of an industrial PC reacts to the pressure of a pointer.
To activate menu items or icons, you just press lightly with a poin-
ter on the screen instead of using a mouse click. If letters or num-
bers have to be entered, dialog boxes with key panels appear on
the screen (see also WinLas manual).
PC from TRUMPF Laser If you got your operating PC from TRUMPF Laser, all technical
requirements are already met. The software for operating the laser
device is already installed.
PC already available On an already available PC, WinLas can be used with the following
operating systems:
Operating Sys- Service

Verison
tems Pack
English is standard.
Windows NT 4.0 6a
German is possible.
Windows 2000 English is standard.
2
Professional German is possible.
English is standard. When extended
1 recom-
Windows XP by the MultiLanguage package, it is
mended
Professional possible to switch to other languages.
2 possible
German is possible.
Tab. 3-3
3-36 Operating-PC 2008-01 20-05-15-A1-CR02

The PC must meet the following minimum requirements:
Windows NT 4.0 Windows 2000 Windows XP

Pentium ≥ 500 Pentium≥ 500 Pentium ≥ 500
CPU
MHz MHz MHz
Main memory ≥ 128 MB ≥ 256 MB ≥ 256 MB
Screen resolution ≥ 800 x 600 ≥ 800 x 600 ≥ 800 x 600
Hard disk > 4 GB > 10 GB > 20 GB
Memory available
> 1,25 GB > 1,25 GB > 1,25 GB
on hard disk
CD-ROM required
Ethernet connec- required for the connection between operating PC and
tion laser control
Modem according required for the telepresence option (see "Telepresence",
to V.90 Standard pg. 3-52)
Tab. 3-4
These specifications were valid at the time of printing this docu-

ment. They are subject to modifications. TRUMPF Laser would be
happy to give you the latest update upon request.
Assistance from service Make sure to enlist the help of the TRUMPF Laser service division
division for installing WinLas. The service division has the necessary ex-
pertise for complete and correct installation of WinLas for your
application.
Note
Do not install any further software on the operating PC of your
laser device. Software which has not been expressly released
for installation by TRUMPF Laser may result in faults and
malfunction.
Work required for eliminating trouble and malfunction caused
by installation or operation of not approved software cannot
be carried out within the scope of the warranty. Costs for such
work have to be borne by the customer.
TRUMPF Laser cannot be held liable for damage resulting

from the installation or operation of software not approved by
TRUMPF Laser.
20-05-15-A1-CR02 2008-01 Operating-PC 3-37

16. Control panel
3 2
1 EMERGENCY STOP pushbut- 3 CONTROL ON button

ton
2 Signal lamp "Mains On" 4 CONTROL OFF button
Fig. 3-40
The control unit of the laser device can be activated and deactiva-
ted on the control panel. In case of emergency, an
EMERGENCY-STOP pushbutton enables a quick deactivation of
the laser device.
You can operate the laser device without a control panel. The
control can be activated externally or by means of the main switch
of the laser device. For this, the EMERGENCY STOP interface and
the start-up interface (X8 on SUN5 board) has to be wired accor-
dingly. More information can be found in the interface description
EMERGENCY STOP.
3-38 Control panel 2008-01 20-05-15-A1-CR02

17. WinLas program
WinLas is a program which has been developed by TRUMPF La-

ser for the operation, control and programming of your laser devi-
ce. Almost every operating step takes place via WinLas.
The following sections contain brief descriptions of the functions
and interface of WinLas.
Instructions for operating the laser device with the WinLas program
are contained in chapter "Operation".
More detailed information can be found in the WinLas manual.
17.1 Functions of the WinLas program
WinLas is a universal program for TRUMPF Laser laser devices. It

assists you in the following tasks:
Operating the laser device:
– Starting and stopping the laser
– Selecting the operating mode
– Resetting the laser device.
Monitoring the laser device:

– Querying the status of the system and operating data
– Displaying fault monitoring and monitoring messages
– Carrying out service functions.
Creating pulse shapes and laser programs:

– Defining pulse shapes
– Determining pulse trains
– Selecting light path
– Programming sequences
– Transferring pulse shapes and laser programs to the laser
control.
20-05-15-A1-CR02 2008-01 WinLas program 3-39

17.2 Main screen
1 2 3 4 5
7 6
1 Menu bar 4 Status indicator 6 Power display

2 Status line 5 Icon bar 7 Soft key bar
3 Message line
Areas of the WinLas main screen Fig. 3-41
3-40 WinLas program 2008-01 20-05-15-A1-CR02

Menu
Fig. 3-42
The menu items for operating, programming and setting the laser
device, as well as for service and help, are to be found in the menu
bar.
The menu items of the main menu and submenus can be selected
by:
• mouse click
• hotkey
Selecting menu items with 1. Press <F10>.

the hotkeys 2. Press <1> to <7> according to the numbers preceding the
menu items of the main menu and submenu.
Example 3. To open the pulse shape editor:

Press <F10>, <2>, <2>.
Soft keys
Fig. 3-43
Functions can be called up via soft keys.

Active soft keys are designated by a graphic symbol or a short text
indicating the function.
Soft keys can have different assignments in different program sta-
tes.
The soft keys can be selected by:
• mouse click
• function keys.
Example To call up the editor:

click Editor.
or
press <F9>.

Icon bar
Icon bar of the basic functions Fig. 3-44
The basic functions of the laser device are activated by way of:
• icons on the screen
• function keys in conjunction with the <Ctrl> key.
Example To turn on the laser:

Click Laser on/off.
or
Press <Ctrl >+ <F2>

Power display
Fig. 3-45
The current laser power and the course taken by laser power in
terms of time over the past minutes are displayed on the main
screen.
The display for change in the laser power over time can be activa-
ted as follows:
1. Select Configuration >System settings >Parameters.

2. For the WL_MainDlgPowerChart parameter enter "TRUE".

Selecting light path
Selection list for light paths Fig. 3-46
The light paths that are possible with the optical arrangement of a
laser device are programmed ex works.
Selecting light path 1. Open ”light path" selection list.

2. Select a light path.
The selected light path is displayed in the window. The switches

and shutters are set automatically in accordance with the selected
light path.

Status indicator
Fig. 3-47
The status display shows the most important status values of the
laser device on the screen. It is divided into 2 areas:
Laser and monitoring status
Light path status.
Laser and monitoring status The displays are LED imitations. They are used to display status
information in different colors:
green: control command executed, safe state, e.g. ”laser is on"
red: unexpected state, alarm, e.g. ”fault"
black: signal not active.
More information about the laser status is given in chapter "Opera-

tion".
More information about the monitoring status is given in chapter
"Conduct in case of service interruptions".
Light paths status If the central shutter (VZ) is open, it is represented in bold charac-
ters.
The number of the selected light path is represented in bold cha-
racters. For indicating the status, the light path numbers are high-
lighted in color.
Color Safety circuit status

• Safety circuit ASV board closed
Gray (basic
• Two-channel safety circuit of ILN box closed.
status)
• Laser light cable OK.
• The safety circuit of the ASV board is open because the
Yellow
laser light cable is defective or not connected correctly.
• The safety circuit of the ASV board is open because the
Red two-channel safety circuit of the ILN box is open.
• Laser light cable OK.
Red and yellow indicate an open safety circuit of the ASV board. As both
colors cannot be displayed simultaneously, yellow takes precedence over
red. A statement about the yellow status of the two-channel safety circuit is
thus not possible.
Tab. 3-5
More information on the light paths status:
(see "Dialog “Light path overview“", pg. 3-48).

17.3 Dialogs
Fig. 3-48
When selecting menu items or soft keys, dialogs with input fields,
soft keys and list fields open. It is thereby possible to control pro-
gram functions which are not accessible from the main screen.

Dialog box “Select operating mode”
1 Display of the set operating 2 Soft key for opening the ”Select
mode operating mode" dialog box
Elements for operating mode on the main screen Fig. 3-49
The operating mode of the laser device is selected in the ”Select

operating mode" dialog box. The appropriate input field for the
parameters appears on the main screen.
Opening dialog box Click Mode.

or
Press <F8>.
The ”Select operating mode” dialog box is opened.
Dialog box “Select operating mode” Fig. 3-50
The WinLas manual contains information about further operating

steps.

Dialog “Light path overview“
Fig. 3-51
The WinLas main screen contains arrows leading to the dialog

“Light path overview”:
Fig. 3-52
Visualization of the light paths in the dialog "Light path overview”

allows to display the statuses of all components integrated in the
light path.
Faults on the light path can thus be localized and the statuses of
the different components can be checked.
The dialogs of the different light path components can be selected

via the dialog “Light path overview”:
LLK (laser light cable)
SIK (safety circuit)
PILOT (pilot laser)
PFO (Programmable focusing optics)
CFO (controlled focussing optics)

Symbols Meaning and function of the buttons contained in the dialog “Light
path overview” are described below:
Button Meaning Function
Close dialog Close dialog
Opens the dialog ”CFO light path

Light path locked
overview“
Opens the dialog ”CFO light path

CFO changed
overview“
Opens the dialog of the component

Fault
in question

Monitoring
in question
CFO not plugged in No function, serves for information

Status OK
in question
Reset Activates a Reset in the ligth path
Tab. 3-6

17.4 User levels
The various user levels permit different authorizations in operating

the program. Certain program functions may be activated, for
example, by service staff only.
Up to 100 user levels are possible. At present 12 of them are defi-
ned.
User
Designation Meaning
level No.
Monitoring operational values, without
0 Display the menus ”Measurement" and ”Diagno-
sis", displaying messages
Displaying operational values of the
10 Operation 1
menus ”Measurement" and ”Diagnosis"
20 Operation 2 Not yet specified
Pump capacity optimization (POP),
30 Maintenance software update, editing of light path
names
Creating, changing and deleting pulse
40 Programming 1
shapes and laser programs.
Creating, changing and deleting pulse
shapes and laser programs with the
41 Programming 2
possibility to modify light paths of
existing programs.
Changing settings without significance
50 Integration
for safety
Changing settings which are significant
60 Administration for safety, assigning workstation, incor-
porating SIK into laser ready
70 THL VS Start-up, changing light path (shutters)
80 THL PAG Commissioning, device acceptance
Software development at TRUMPF
90 THL EES
Laser
100 THL DEV Developers
Defined user levels Tab. 3-7
The user level is set by entering a password.

Every user level also includes the authorization to user levels ha-
ving a smaller number. Example: User level 30 includes the autho-
rization to user levels 0, 10 and 20.

Display of the user level Fig. 3-53
The number of the set user level is indicated on the main screen.
Selecting user level
Menu "Select user level" Fig. 3-54
1. Select >Configuration >View >Select user level .

The ”Select user level" dialog box appears on the screen.
2. Enter password of the desired user level.

The set user level is displayed (see "Fig. 3-53", pg. 3-51).
Note
The passwords for the user levels must be familiar only to tho-
se persons who are authorized for them.

18. Telepresence
What does telepresence Telepresence is an optional TRUMPF Laser service.

mean?
TRUMPF Laser staff can access the operating PC of the laser
device via telephone line and carry out the following operations:
Remote operation of the laser device
Displaying operational values
Troubleshooting
Read-out of operational data and transfer them to TRUMPF
Laser
Changing the parameters
Updating the software.
Support by TRUMPF Laser With the telepresence option TRUMPF Laser can assist you in:
using the laser device most efficiently for your application.
recognizing the necessity of preventive maintenance.
locating faults quickly and taking the appropriate steps for eli-
minating them.
operating the operating PC always with the most up-to-date
software.
The access to the option Telepresence can be realized optionally

directly via an analog modem, a Remote Access Service (RAS) or
a Virtual Private Network (VPN).
Safety certificate The staff of TRUMPF Laser uses the "TRUMPF Telepresence
Portal" for telepresence. The "TRUMPF Telepresence Portal"
meets the severe safety requirements of the international certifica-
tion standard for information safety management systems (ISO
27001).
18.1 Direct connection over an analog mo-

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

Signal shape: analog
Connection: RJ 12
In the operating PCs delivered by TRUMPF Laser, an international

modem is included.
Required information TRUMPF Laser requires the following information to ensure a di-
rect connection:
telephone number of the modem-connection.
serial number of the laser device from TRUMPF Laser.
name of the contact person for the laser device.
telephone number for questions.
3-52 Telepresence 2008-01 20-05-15-A1-CR02

18.2 Connection via RAS
The access via a Remote Access Service (RAS) can be realized in

the following ways:
RAS via ISDN or analog telephone connection
Special connection according to customer specification.
Required information For a connection via RAS TRUMPF Laser requires the following
information:
Telephone number of the RAS-access.
IP-address of the operating PCs.
PC-name.
Device number of the laser devices from TRUMPF Laser.
IP-addresses of the laser devices from TRUMPF Laser.
Name of a contact person for the laser device.
Telephone number of a telephone set for further inquires.
User name and password of the access authorization.
If not automatically assigned by the server, still the following infor-

mation is required:
Primary DNS
Secondary DNS
Primary WINS
Secondary WINS
Domain
18.3 Connection via VPN
The access via a Virtual Private Network (VPN) can be realized by

the following ways:
VPN via Internet
Special connection according to the customer’s specification.
Required information For the access via VPN TRUMPF Laser requires the following
information:
IP-address of the VPN-access
User name and password and access authorization.
The following information about the server in use is required:

VPN-software in use.
VPN-access data.
IP-address of the operating -PC.
PC-name.
Device numbers of the laser devices from TRUMPF Laser.
IP-addresses of the laser devices from TRUMPF Laser.
Name of the contact person for the laser device.
Telephone number of a telephone set for further inquires.
20-05-15-A1-CR02 2008-01 Telepresence 3-53

18.4 User configuration of the operating-PC
For the full TelePresence access on the PC and in order to be able

to carry out possible software updates, a user with the following
characteristics must be installed:
local user.
local administrator rights.
RAS-access rights (if required).
user name: can be obtained from TRUMPF Laser.
password: can be obtained from TRUMPF Laser.
These characteristics are already available at computers supplied

by TRUMPF Laser.
18.5 Firewall configuration
Information about the firewall configuration is to be found in the

following documents:
Interface description IAONA Security Datasheet for opera-
ting-PC
Interface description IAONA Security Datasheet for TRUMPF
laser devices
The IOANA Handbook for Network Security (Download unter
www.iaona.org)
If you need further information on this subject, contact TRUMPF

Laser.
3-54 Telepresence 2008-01 20-05-15-A1-CR02

Chapter 4
Operation
1. Operating elements and indicators ............................. 4-3

1.1 Main switch ...................................................................... 4-3
1.2 Front side of the laser device........................................... 4-4
1.3 Laser warning lamps........................................................ 4-6
1.4 Control panel ................................................................... 4-7
2. Switching the laser device on and off ......................... 4-8

2.1 Switching on .................................................................... 4-8
2.2 Switching off in case of malfunction and
emergencies .................................................................. 4-10
2.3 Switching on after E-STOP............................................ 4-10
2.4 Switching off after finishing work ................................... 4-11
3. Operating laser device with WinLas .......................... 4-12

3.1 Selecting operating mode and entering parameters ..... 4-12
3.3 Activating the Laser ....................................................... 4-15
3.4 Responding to messages .............................................. 4-18
3.5 Generating pulse shapes............................................... 4-20
3.6 Creating laser programs ................................................ 4-21
20-05-15-A1-CR02 2008-01 Operation 4-1

3.7 Programming light paths................................................ 4-22
3.8 Operating pilot laser....................................................... 4-23
Setting pilot laser mode ............................................ 4-24
Switching the pilot laser on and off........................... 4-25
3.9 Program management ................................................... 4-29
Save programs ......................................................... 4-29
4. Controlling the laser device externally...................... 4-30

4.1 Defining the laser power with analog interface.............. 4-31
4.2 Defining the laser power through a field bus
(option)........................................................................... 4-35
4.3 Controlling the laser device functions externally ........... 4-38
Defining the change in laser power .......................... 4-39
4.4 Operating laser device in MixMode ............................... 4-41
4.5 TRUMPF LASERNETWORK (Option) .......................... 4-42
4-2 Operation 2008-01 20-05-15-A1-CR02

1. Operating elements and indicators
1.1 Main switch
The main switch has 2 positions: ON and OFF.
ON OFF
Fig. 4-1
On Switch on the laser device with the main switch in position ON.
OFF In OFF position:

the main switch disconnects all poles from the mains
the main switch can be protected against unauthorized swit-
ching-on by means of shackle type locks.
Always protect the main switch against unauthorized switching-on

during service 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.
20-05-15-A1-CR02 2008-01 Operating elements and indicators 4-3

1.2 Front side of the laser device
1 2 3 4 5
1 EMERGENCY STOP 4 Laser warning lamp

pushbutton
2 Signal lamp "Mains On" 5 Key-operated switch
3 Signal lamp "Monitoring"
Fig. 4-2
EMERGENCY STOP The laser and the cooling unit are immediately switched off when
pushbutton the pushbutton EMERGENCY STOP is pressed. In particular, no
more laser light is emitted.
The EMERGENCY STOP pushbutton can be integrated in the
Emergency Stop circuit of a system. With this pushbutton, the ent-
ire system can be cut off. More information can be found in the
interface description EMERGENCY STOP.
Signal lamp "Mains On" The signal lamp "Mains on" lights up:
when the laser device is connected to the power supply
and
the main switch is in ON position.
4-4 Operating elements and indicators 2008-01 20-05-15-A1-CR02

Signal lamp "Monitoring" The signal lamp "Monitoring" is lit when:
an operating value has exceeded the monitoring limit.
a malfunction has occurred.
the interlock unit has been interrupted.
If the signal lamp "Monitoring" is lit, a message is displayed. The

message contains information about cause and measures to eli-
minate the problem.
Laser warning lamp The laser warning lamp is lit when:

the laser is ready for emitting laser light, even if no laser light is
emitted at the processing point yet ("laser on" status).
Key-operated switch
0 0
I
A B
Fig. 4-3
Activation of the laser by an unauthorized person can be prevented

by means of the key-operated switch. To do so, turn the key to the
position 0 (chart A) and be withdrawn.
The key has to be inserted for operation. The key-operated switch
has to be turned to the right.

1.3 Laser warning lamps
Laser warning lamp on top of the laser device Fig. 4-4
Laser warning lamp in the laser device Fig. 4-5
Laser warning lamp The laser warning lamp is lit when:

the laser is ready for emitting laser light, even if no laser light is
emitted at the processing point yet ("laser on" status).
Additional laser warning lamps can be connected to the SUN board

of the mains distribution. More information can be found in the
interface description EMERGENCY STOP.
4-6 Operating elements and indicators 2008-01 20-05-15-A1-CR02

1.4 Control panel
3 2
1 EMERGENCY STOP pushbut- 3 CONTROL ON button

ton
2 Signal lamp "Mains On" 4 CONTROL OFF button
Fig. 4-6
EMERGENCY STOP push- The Emergency Stop pushbutton has the same function as the
button pushbutton at the front of the laser device (see "Front side of the
laser device", pg. 4-4).
Signal lamp "Mains On" The signal lamp ”Mains on" has the same function as the signal
lamp on front of the laser device (see "Front side of the laser devi-
ce", pg. 4-4).
CONTROL ON button The control unit of the laser device is activated when you press the
"Control ON", button. The control unit is ready after a short waiting
time. All functions of the laser device can be carried out when the
control unit is turned on.
CONTROL OFF button The control unit of the laser device is deactivated after approx. 8
seconds when you press the "Control OFF", button. Operating the
laser is not possible while the control unit is switched off.
Note
You can operate the laser device without a control panel. The
control can be activated externally or by means of the main switch
of the laser device. For this, the EMERGENCY STOP interface and
the start-up interface (X8 on SUN5 board) has to be wired accor-
dingly. More information can be found in the interface description
EMERGENCY STOP.

2. Switching the laser device on and off
2.1 Switching on
Condition
The following lines and cables are connected:
– Electrical mains connection
– External cooling circuit.
– Laser light cable.
– Control lines between operating PC and laser device
– Control lines to periphery, if applicable.
1. To activate the external cooling: Open valves in the inflow and

return line of the external cooling circuit
2. If a chiller is used: switch it on.
Key-operated switch Fig. 4-7
3. Turn the key-operated switch into position I.
4-8 Switching the laser device on and off 2008-01 20-05-15-A1-CR02

ON OFF
Fig. 4-8
4. Turn main switch of the laser device to the
ON position.
The signal lamp "Mains on" lights up.
Control panel, ON button Fig. 4-9
5. Press ON at the control panel.

The control unit of the laser device is switched on. Running
noises of the laser device can be heard.
6. Turn on the operating PC.
After a few seconds the main screen of the WinLas program
appears.
The laser device has been turned on.
Tip
If the laser device is operated without control panel, the ”Control
system on" signal has to be generated from an external control
unit. More information can be found in the interface description
EMERGENCY STOP.
20-05-15-A1-CR02 2008-01 Switching the laser device on and off 4-9

2.2 Switching off in case of malfunction
and emergencies
Press EMERGENCY STOP pushbutton at the control panel or

at the front of the laser device.
Laser and cooling unit of the laser device is switched off. No

laser light in particular can be emitted after the EMERGENCY
OFF button has been operated.
The control unit of the laser device remains switched on.
2.3 Switching on after E-STOP
1. Turn depressed E-STOP pushbutton in direction of the arrow.
The pushbutton becomes unlocked. Deactivated functions of

the laser device are rendered ready for service.
2. Note fault monitoring and monitoring messages.

3. Eliminate the cause of faults (see chapter "Conduct in case of
service interruptions").
4. In the Program WinLas, click on Reset (see "Responding to
messages", pg. 4-Fehler! Textmarke nicht definiert.).
The control unit is reset to original condition.
The laser device is again ready for operation.
4-10 Switching the laser device on and off 2008-01 20-05-15-A1-CR02

2.4 Switching off after finishing work
Note
When switching off, it is absolutely required to proceed in the indi-
cated order, as otherwise there can be software and hardware
damage in the control of the laser device.
Turning off PC
Fig. 4-10
1. Select operation > Turn off PC.

WinLas is finished and Windows is shut down.
2. Switch off operating -PC.
Switching off the laser device
Fig. 4-11
3. Press the push-button OFF (AUS) on the control panel.

After about 8 seconds, the control of the laser device and the
control panel are switched off.
4. Turn the main switch of the laser device to the position OFF
(AUS).
5. If the laser device shall be protected against unauthorized use:
turn key-operated switch to the left and remove key.
The laser device is switched off.
20-05-15-A1-CR02 2008-01 Switching the laser device on and off 4-11

3. Operating laser device with WinLas
This section gives information on the most important function of the

program WinLas for the control of the laser device. Further infor-
mation is to be found in the WinLas manual.
3.1 Selecting operating mode and entering

parameters
Selecting operating mode
Dialog box “Select operating mode” Fig. 4-12
1. ClickMode.
or
Press<F8>.
The ”Select operating mode” dialog box is opened.
"Default values" screen Fig. 4-13
2. Click Laser program, Square pulse, Contin. wave, Pulse train

or Contin.pulse.
or
Press one of the function keys <F3> to <F7>.
The desired operating mode is selected. The operating
mode is indicated by a symbol in the status line of the main
screen (arrow).
The "Default values" screen area exhibits input fields.
4-12 Operating laser device with WinLas 2008-01 20-05-15-A1-CR02

Entering parameter 3. Enter parameter, e.g. laser power in the square-wave pulse
mode.
The operating mode is indicated on the screen:

Symbols: (see "Fig. 4-12", pg. 4-12).
Representation: (see "Fig. 4-13", pg. 4-12) (arrow).
Next time the laser is started, it will operate in the selected mode.
The WinLas manual contains further information about the opera-
ting mode.
3.2 Selecting light path
The optical arrangement of the laser device mostly permits selec-

tion between several laser light cables through which the laser
light can be conducted to the machining point. The light path which
the laser beam is to take can be selected in WinLas.
The light path can also be selected for every step of a laser pro-
gram.
Selecting light path
”Light path" selection field Fig. 4-14
1. Click drop-down arrow.

The ”Light path" selection list is opened.
The ”Light path" selection list is opened. Fig. 4-15
2. Select 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
when the laser is activated next time.
20-05-15-A1-CR02 2008-01 Operating laser device with WinLas 4-13

Editing light path names
Menu: Call ”Edit light path name" dialog box Fig. 4-16
3. Select >Configuration > Edit light path name.

You need a correct authorization, to enter the ligth path name.
Selecting a light path in laser

programs
Laser program editor Fig. 4-17

4. In addition to other settings, the light path
for every program step can be selected in a laser program. For
this purpose the light path is entered in the program line of the
laser program (”light path no." column) in the laser program
editor.
5. Select >Program >Create and change laser program.
The operation of the laser program editor is described in the Win-
Las manual.

3.3 Activating the Laser
Conditions
The laser device has been turned on.
The button >Laser on/off on the screen of the operating PC is
active (black marking).
No fault is displayed in the status field.
The required mode is chosen and laser parameters are ente-
red (see "Selecting operating mode and entering parameters",
pg. 4-12).
If pulse shapes or laser programs are used, they have to be
stored in the laser control unit (see WinLas manual).
The light path is selected (see "Selecting light path", pg. 4-13).
he processing optics are correctly adjusted (see focusing op-
tics manual).
Switching on the laser 1. Click Laser on/off.

or
Press <Ctrl >+ <F2>
The status indicator ”Laser is on" lights up in green
Status display ”Laser is on" Fig. 4-18
So far no laser light is generated in the laser.
Fig. 4-19
After expiry of every 200 operating hours, an automatic pump

module self test is carried out at the next activation of the laser
(clicking on Laser on/off). This process takes approx. 2 minu-
tes.
During the pump module self test, the buttons of the button bar
are represented as inactive (grey). The message Self test ac-
tive is displayed.
After a successful pump module self test, the buttons of the
button bar are active again and the laser device is ready for
use.

Undoing a step 2. Click Laser on/off.
or
Press <Ctrl >+ <F2>
Activating standby operation 3. Click STANDBY.

or
Press <Ctrl>+ <F3 >
Laser light is generated in the laser device. The laser works in

the selected mode. The central shutter is closed. Therefore no
laser light is emitted at the processing point yet.
Status and measured value indicators ”Standby" Fig. 4-20
The status indicator ”Laser ready" lights up in green. The ge-

nerated laser power is indicated (here 400 W).
The laser operates stably right from the beginning when the
central shutter is opened in the next step.

Undoing a step 4. Click STANDBY.
or
Press <Ctrl>+ <F3 >.
Start laser
After the next step is complete, high power laser light will be
emitted from the selected processing optics!
Laser light can cause serious burns to your skin. Direct or
scattered laser light can permanently damage your eyes.
Warning
Do not reach between processing optics and workpiece.
Surround the machining point with a protective cover or wear
laser safety goggles.
5. Click Start / Stop.

or
Press <Ctrl>+ <F4>.
The central shutter is opened. Laser light is transmitted in the

selected mode to the processing point.
Status and measured value indicators after Fig. 4-21

”Start"
The status indicator ”Program active" lights up in green. The

generated laser power is indicated (here 400 W).
A laser program or an operating mode with finite duration (e.g.
a finite pulse train) stops automatically when the defined end is
reached.

Canceling activated mode 6. Click Start / Stop.
or
Press <Ctrl>+ <F4>.
Stop causes:
• a mode without defined end, (e.g. continuous wave or infinite
pulse train) to be completed correctly.
• a laser program or a mode with defined end to be canceled.
3.4 Responding to messages
The control unit monitors numerous operational values of your

laser device.
A monitoring message is displayed on the operating PC as soon

as one of the operational values has reached a monitoring limit
(see chapter "Conduct in case of service interruptions").
Status indicator "Monitoring" Fig. 4-22
The status indicator "Monitoring" lights up in red.
Status indicator "Fault" Fig. 4-23

A fault monitoring message is displayed as soon as a monitored
operational value leaves the permissible range and thus causes a
critical condition (see chapter "Conduct in case of service interrup-
tions"). The status indicators “Monitoring” and “Fault” light up in
red.
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.
Please refer to chapter "Conduct in case of service interruptions"
and the WinLas manual for further information on messages.
Resetting the laser device 1. Eliminate the cause of the message. If necessary, contact the
service division of TRUMPF Laser.
2. Click Reset.
or
Press <Ctrl >+ <F5 >.
The message is reset. The laser device is reinitialized after a

fault has occurred..
The red indicators in the status display go off.
The laser can be activated again.

3.5 Generating pulse shapes
The laser device can create any desired pulse shapes.

A pulse shape editor is integrated in WinLas for generating, alte-
ring and managing pulse shapes.
Pulse shapes can be called:

manually
laser programs.
Pulse shape editor Fig. 4-24
The power points of the pulse shapes can be entered graphically

or by means of a table.
Information on operation of the pulse shape editor is to be found in
the WinLas manual.

3.6 Creating laser programs
A laser program is a sequence of commands and settings which

are executed automatically after start.
A laser program editor is integrated in WinLas for generating, alte-
ring and managing laser programs.
Laser programs can be called:

manually
or externally via a laser device interface.
Laser program editor Fig. 4-25
Laser programs are composed of program lines. The program line

editing is supported by wizards.
Information on operation of the laser program editor is to be found
in the WinLas manual.

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

under WinLas:
Selecting light paths (see "Selecting light path", pg. 4-13).
Editing light path names (see WinLas manual)
Programming light paths.
Managing light paths (see "Program management", pg. 4-29).
Definitions Programming a light path means:

Defining the position of switch mirrors and shutter mirrors in
the optical arrangement.
• Storing the information on mirror positions in a data record for
the light path.
TRUMPF Laser has already programmed all possible light paths

for the optical arrangement of your laser device. Each light path
leads through a laser light cable to a processing point. Two or mo-
re laser light cables may belong to one light path when optical
splitters are used.
Editing light path names Every light path can be given a user name.
Please refer to the WinLas manual for further information on autho-
rization and processing.
Programming light paths Programming light paths should be done exclusively by the
TRUMPF Laser service engineers (from user level 70). This is only
necessary if the optical arrangement of the laser device was
changed in such a way that other light paths become possible or
previous light paths are no longer possible.

3.8 Operating pilot laser
Switching the pilot laser on When the pilot laser is switched on, is determined:
by the set pilot laser mode.
by shutter switch state (shutter closed)
by the value of a signal evaluated in the selected pilot laser
mode.
Pilot laser mode Mode Meaning

0 Pilot laser is constantly switched off.
1 Pilot laser is on if the shutter switch is closed.
The pilot laser is on when the safety circuit of the light path is
2
interrupted.
The pilot laser is active, when
ithe signal PILOT_LASER_ON is set in the laser input word at
3
the control interface
AND the shutter switch is closed.
the signal PILOT_LASER_ON is set in the laser input word at
4
AND the safety circuit of the light path is interrupted.
5 the signal PILOT_LASER_ON is set in the laser input word at
Tab. 4-1

Setting pilot laser mode
Conditions
WinLas has been started
User level 50 or higher has been set.
Fig. 4-26
1. Select the menu item>Configuration>Change system settings.

The dialog box ”Change system settings" appears on the
screen.
2. In the “PilotLaserMode” field, enter the desired mode.
3. Press the function key <F9>.
The dialog box is closed. The desired pilot laser has been set.

Switching the pilot laser on and off
With the pilot laser dialog, the user can switch the pilot laser of the
individual light paths directly on and off.
Pilot laser dialog boxes in WinLas Fig. 4-27
Opening the dialog box 1. Select menu >Configuration >Set-up mode.

or
Select menu >Test >Pilot laser.
The number of light paths displayed corresponds to that actu-

ally present in the optical arrangement of the laser device (here
6).

1 2 3 4
1 Field for light path names 3 Button “Pilot laser off”

2 Button “Pilot laser on” 4 Status indicator
Fig. 4-28
Field for light path names

The field for light path names (pos. 1) displays the name the
user has assigned to the light path (see WinLas manual: sec-
tion “Edit light path names”).
Pilot laser ON 2. Clicking the button “Pilot laser on” (2) switches on the pilot
laser in question.
Pilot laser OFF 3. Clicking the button “Pilot laser off” (3) switches off the pilot
laser in question.
Is it impossible to switch the 4. This may be caused by an active signal at the control interface.
pilot laser on or off by Switch pilot laser on or off via the active signal.
clicking the buttons? or
Switch to a mode in which this signal is active (see section
“Setting the pilot laser mode”).

Status indicator
1 2 4
1 pilot laser 3 Shutter switch

2 Safety circuit 4 Laser light cable
Fig. 4-29
pilot laser Pilot laser status indicator (1):

bright: Pilot laser is on.
dark: Pilot laser is off.
Safety circuit Safety circuit status display for this light path (2):
Symbol visible: Safety circuit has been interrupted.
Symbol invisible: Safety circuit is closed.
Shutter switch Status display for shutter switch:

Symbol horizontal: Shutter closed(see "Fig. 4-29", pg. 4-27).
Symbol inclined: Shutter open(see "Fig. 4-31", pg. 4-28).
Laser light cable Light path status display:

Incoupling of pilot laser beam (see "Fig. 4-30", pg. 4-28).
No incoupling of pilot laser (see "Fig. 4-29", pg. 4-27).

Examples
Fig. 4-30
(see "Fig. 4-30", pg. 4-28) is the display for the following status:
Pilot laser on.
Safety circuit is interrupted.
Shutter closed.
Incoupling of pilot laser beam into the light path.
Fig. 4-31
(see "Fig. 4-31", pg. 4-28) is the display for the following status:
Pilot laser off.
Safety circuit is closed.
Shutter open.
Incoupling of work laser beam into the light path.

3.9 Program management
When saving laser programs, pulse shapes or light paths, the data
are transmitted automatically from the PC to the laser control. The
data on the harddisk of the PC and in the control correspond to
each other.
"Programming" menu Fig. 4-32
Save programs
"Save programs and light paths" dialog box Fig. 4-33
1. Select Programming > Save programs and light paths. The

dialog box "Save programs and light paths" opens.
2. For further operation steps see WinLas manual.

4. Controlling the laser device externally
The laser device can be controlled via interfaces by:

externally defining the time course of the laser power
externally controlling the entire laser device.
How to operate the laser device manually with WinLas is described

in section "Operating laser device with WinLas".
Externally defining the laser The set point for the laser power can be externally defined, e.g. by
power a function generator, a CNC control unit or a robot. You have two
possibilities:
with an analog voltage or current signal through the analog
input card
through a field bus (Interbus-S, Profibus-DP or DeviceNet ).
Controlling the laser device The following laser device functions can be externally controlled
functions externally via the control unit I/O interface, by using, for example, a PLC:
Laser on / off.
Standby.
Start / Stop and call-up of laser programs.
Reset.
The condition for externally controlling the laser device is that ope-
rating modes and laser parameters are stored in laser programs.
Laser devices of TRUMPF Laser can be controlled by external
control units (e.g. PLC) via a parallel input/output interface or field
bus boards. Depending on the used interface mode, max. one
parallel input/output interface or 3 field bus boards can be used in
the control unit of the laser device.
For an external controlling of the laser device, both following inter-

face modes are possible:
Standard mode: max. 1 parallel input/output interface or 1 field
bus board
Multi-PLC Interface (MPI): max. 3 field bus boards in the
control unit of the laser device.
Note
With the option MPI, in connection with an Interbus-Master in the
control unit of the laser device, it is possible to connect up to 32
external control units to the laser device.
The Multi-PLC Interface (MPI) enables the use of TRUMPF

LASERNETWORK (TLN or TLN-fc).
4-30 Controlling the laser device externally 2008-01 20-05-15-A1-CR02

4.1 Defining the laser power with analog
interface
The laser power can be defined through an analog current or vol-

tage signal at the interface X1 of the analog input card. The analog
input card has the designation AEF.
Refer to the interface description Analog input AE for particulars

on:
pin assignment of the interface X1.
signal level for current or voltage.
adjustable input resistances.
signal delay.
Condition
The following values are correctly set on the analog input card:
– Signal level
– input resistance
– Signal delay.

An electric signal source, which releases signals in one of the
ranges specified in the interface description (e.g. voltage
0...10V).
Cable from the signal source to the interface X1.
If switch positions on the analog input card have to be checked or

altered:
20-05-15-A1-CR02 2008-01 Controlling the laser device externally 4-31

Setting interface parameters
VMOD Diag.Error Diag. Diag.

Diag.
VHLM
X22
Diag. Diag.Error
X23
X21
X24
X7
X3
X25
ASV IIOS LLKM
Analog input card AEF Fig. 4-34
1. Switch off the laser device.

2. Remove analog input card.
3. Set switches S1 to S8 and X2 on the analog input card, as
corresponds to the use and data of the signal source (see in-
terface description Analog input AE).
4. Reinsert analog input card.
5. Switching on the laser .
Applying analog signal 6. Connect analog input card to the signal source.
Selection of the external interface "Power" Fig. 4-35
7. Click the continuous wave operating mode or square-wave

pulse operating mode in the WinLas program(see "Selecting
operating mode and entering parameters", pg. 4-12).
The desired operating mode is selected. The "Default values"
screen area exhibits input fields.
8. Click the box "opt." in the "Power" line.
The box is marked by a tick.
9. Select ANALOG .

Activating the laser

Warning
Do not reach between focusing optics and workpiece.
Wear safety goggles suitable for the wavelength of the
laser light (see notice signs).
10. Click Laser on/off.

11. Click STANDBY.
12. Click Start / Stop.
The laser power now follows the signal applied at the interface
X1.
Continuous wave (external) Square-wave pulse (external)

External setpoint default:
Laser power in the laser device:
Laser power at the machining point:
External setpoint default Tab. 4-2
Note
The signal delay (setting of S3 on the analog input board) is:
Standard: 0,1 ms
In case of a faulty input signal: 5 ms
This results in the highest possible frequency.
Tab. 4-3
Concluding external power 13. To conclude the emission of laser light:

default Click Start / Stop.
or
Press <Ctrl>+ <F4>.
Note
The emission of laser light is stopped automatically after the
set pulse duration has elapsed if the mode "Square-wave pul-
se" is chosen.

Fig. 4-36
14. Click the box "opt." in the "Power" line
The box is empty.
The setpoint for the laser power is now internally generated.

4.2 Defining the laser power through a
field bus (option)
f the laser device is equipped for control through field bus, the laser
power can be defined externally through the field bus. The control
unit of the laser device can be equipped optionally for the following
field bus systems:
Interbus
Profibus-DP
DeviceNet
Conditions
The control system of the laser device must be connected with
the field bus.
A field bus master must be prepared for transmitting control
commands. The format indicated in the interface description of
the field bus has to be observed.
When control takes place through a field bus, the I/O interface is
replaced by a field bus card.
Diag.
VHLM
X22
Diag. Diag.Error
X23
X21
X24
X7
X3
X25
ASV IIOS LLKM
Field bus card Fig. 4-37
In this case, an interface description of the installed field bus type

is contained in the device documentation. The information it con-
tains replaces the information on the I/O interface given in thein-
terface description for the laser device.

Controlling the laser power
Selection of the external interface "Power" Fig. 4-38
1. Click the Continuous wave or Square-wave operating mode in

the WinLas (see "Selecting operating mode and entering pa-
rameters", pg. 4-12).
The desired operating mode is selected. The "Default values"
screen area exhibits input fields.
2. Click the box "opt." in the "Power" line.
The box is marked by a tick.
3. Select the interface that is used for controlling the input signal.
Interface Entry in the selection field

Interbus-S-Input-Word x IBSIWx
Profibus-Input-Word x PBIWx
DeviceNet-Input-Word x DNIWx
Tab. 4-4
"x" indicates the number of the field bus data word. Standard
value for x is 3.

Warning
4. Activating laser light (see "Activating the Laser", pg. 4-15):

– Click Laser on/off.
– Click STANDBY.
– Click Start / Stop.
5. Transmit data through the field bus to the laser device.
The laser power now follows the values transmitted by the se-
lected field bus.
Conclude power default 6. To conclude the emission of laser light:

through field bus: Click Start / Stop.
or
Press <Ctrl>+ <F4>.

Note
The emission of laser light is stopped automatically after the
set pulse duration has elapsed if the mode "Square-wave pul-
se" is chosen.
Fig. 4-39
7. Click the box "opt." in the "Power" line
The box is empty.
The setpoint for the laser power is now internally generated.

4.3 Controlling the laser device functions
externally
The most important functions which can be manually controlled by

way of the WinLas program can also be controlled by way of an
interface. This allows the integration of the laser device in an au-
tomated environment.
The following functions can be controlled with an interface:

Laser on / off.
Standby.
Reset.
Control signals can be entered and status signals can be read out
by way of the following interfaces:
I/O interface.
Interbus-S.
Profibus-DP .
DeviceNet .
Diag.
VHLM
X22
Diag. Diag.Error
X23
X21
X24
X7
X3
X25
ASV IIOS LLKM
Location of the interface for external control Fig. 4-40
Standard The control unit of the standard version provides a board with I/O
interface.
Information on signal level and pin assignment of the connector are
contained in the interface description for the laser device.

Field bus If the laser device is equipped for control through field bus, a slave
card of the chosen field bus system is provided in the control, at
the place where normally the I/O card is.
Please refer to the interface description of the field bus for infor-
mation on pin assignment, signal level and data structure.
Required knowledge for Pin assignment, signal level and data structure of the interface
external control (see interface description).
Handling of external control, e.g. PLC, field bus master (see
documentation of the PLC etc.).
Generating and storing pulse shapes (see WinLas manual).
Generating and storing laser programs (see WinLas manual).
The hardware requirements for the control of the laser device have
to be met. In particular there must be an appropriate connection
between laser device and the external control.
Note
The signal connection between laser device and external control
unit must have adequate interference immunity.
Defining the change in laser power
1. Carefully plan the change in laser power for the individual

phases of machining the workpieces.
2. Determine for which phases:
– constant power values are used in laser programs
– pulse shapes are used
– the course of power is externally defined.
3. Generate pulse shapes and store them in the control unit of the
laser device (see WinLas manual).
4. Create laser programs and store them in the control unit of the
laser device (see WinLas manual).
Note
Laser programs offer the following possibilities of determining
the change in laser power:
– Using constant values (square-wave pulse, continuous
wave).
– Calling up pulse shapes.
– Externally defining the laser power:
· analog.
· through field bus interface, if present.

Fig. 4-41
5. Activate "External activation" at the laser
device (see interface descriptions).
The status indicator "External activation" lights up in green.
The laser device operates in the automatic mode. With the
signal Lock operating unit, the manual operation by way of the
operating PC is blocked. The operating PC then only serves as
display for messages.
6. EProgram external control (PLC, field bus master etc.). Incor-

porate the call-up of the prepared laser programs in the correct
order in the control program.
7. Synchronize external analog signals which define the course of
the laser power (insofar as is applicable).
8. Pay attention to correct processing of status signals.
Note
When all preparations have been done, the laser device can
also be operated without operating PC. TRUMPF Laser re-
commends using the operating PC in any case as display for
monitoring and fault monitoring messages.

Warning
9. Activate external control.

10. Monitor the operation.
11. React to monitoring and fault messages (see chapter "Conduct
in case of service interruptions").
12. When all program steps are executed correctly: hand system
over to operating staff.

4.4 Operating laser device in MixMode
In the MixMode, the laser device is operated manually via the

operating PC, but single functions can also be controlled via the
control interface.
The following functions can be controlled manually or via the

control interface (OR operation):
Laser on / off.
Standby.
These functions are controllable via the control interface, when the
corresponding variables in the system settings have the value
TRUE.
Click >Configuration >Change system settings.
Variable Value Meaning

Laser on/off controllable via
TRUE
interface
MixMode_ PLCLaserOn
Laser on/off not controllable
FALSE
via interface
Program start/stop control-
TRUE
lable via interface
MixMode_PLCStart
Program start/stop not
FALSE
controllable via interface
Standby controlled via
TRUE
MixMode_ interface
PLCStandbyON Standby not controlled via
FALSE
interface
MixMode variable values Tab. 4-5
Fig. 4-42
The "External activation" entry at the laser device must be deacti-

vated (see interface descriptions). The status indicator "external
activation" does not light up.

4.5 TRUMPF LASERNETWORK (Option)
Optionally, the laser device can be equipped with TRUMPF

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

Multi-PLC Interface (MPI)
Interface LASERNETWORK (ILN)
Ethernet
MPI The Multi PLC Interface is a software interface of the laser device
for exchanging control signals with a maximum of 32 external
control units. The external control units are connected with the
laser device through field bus components.
MPI can be used efficiently if the laser power of a laser device has
to be requested by various control units.
ILN The interface LASERNETWORK contains signal lines for:

light path coding
two-channel safety circuits.
Ethernet The laser device can be connected to other devices in a local net-
work (LAN) via Ethernet.
Detailed information can be found in the Technical Information
TRUMPF LASERNETWORK and other documents available from
TRUMPF Laser.

Chapter 5
Maintenance
1. General notes................................................................. 5-4
2. Material ........................................................................... 5-5

2.1 Wearing parts .................................................................. 5-5
2.2 Tools and auxiliaries ........................................................ 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 Opening and closing the door to the user room .............. 5-9
3.3 Opening and closing hoods ........................................... 5-10
3.4 Removing side panel diode power supply ..................... 5-11
4. Hose connections........................................................ 5-12

4.1 Connecting the hose...................................................... 5-12
4.2 Disconnecting the hose ................................................. 5-12
5. Removing the securing device from the stop

valve .............................................................................. 5-13
20-05-15-A1-CR02 2008-01 Maintenance 5-1

6. Maintenance overview................................................. 5-14
7. Replacing the pump module....................................... 5-15

7.1 Preparing the laser device ............................................. 5-17
7.2 Removing the pump module.......................................... 5-19
7.3 Inserting the new pump module .................................... 5-22
7.4 Final procedures ............................................................ 5-26
8. Removing and mounting the laser light cable

LLK-D ............................................................................ 5-29
8.1 Removing LLK-D ........................................................... 5-30
8.2 Mounting the LLK-D....................................................... 5-38
9. Maintaining laser light cable ...................................... 5-46

9.1 Cleaning the protective sleeve along with the cover
slide on the LLK-D ......................................................... 5-46
9.2 Replacing the protective sleeve along with the
cover slide...................................................................... 5-47
10. Laser cooler ................................................................. 5-49

10.1 Topping up cooling water............................................... 5-50
10.2 Cleaning the tank........................................................... 5-52
10.3 Replacing the deionizing filter........................................ 5-55
10.4 Cleaning the particle filter .............................................. 5-58
10.5 Replacing filter element in the fine filter......................... 5-60
10.6 Replacing the water in the tank ..................................... 5-63
Emptying the tank ..................................................... 5-63
Filling in cooling water .............................................. 5-64
10.7 Maintaining the entry filter.............................................. 5-65
Backfush the entry filter ............................................ 5-65
Clean the entry filter ................................................. 5-67
10.8 Check cooling block (Option)......................................... 5-70
10.9 Emptying and filling the cooling unit .............................. 5-71
Emptying the cooling unit of the laser device ........... 5-71
Filling the cooling unit ............................................... 5-87
11. Maintenance of the air cleaner ................................... 5-90

11.1 Replacing filter cartridge in the activated carbon
filter ................................................................................ 5-92
11.2 Replacing the filter cartridges in the water
separator and the submircofilter .................................... 5-95
11.3 Filter cartridge in the intake filter ................................... 5-97
11.4 Completely replacing the air cleaner ............................. 5-98
11.5 Changing the filter mat................................................. 5-100
12. Electrics ...................................................................... 5-101
5-2 Maintenance 2008-01 20-05-15-A1-CR02

12.1 Identifying blown electrical fuses ................................. 5-101
12.2 Activating an automatic circuit breaker........................ 5-103
12.3 Changing a fuse........................................................... 5-104
12.4 Replacing a microfuse ................................................. 5-106
20-05-15-A1-CR02 2008-01 Maintenance 5-3

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

operation of the laser device and for the quality of the working re-
sult.
The laser device requires little maintenance. All important functions
are electronically monitored. A monitoring message, which is indi-
cated by the laser device, can call for maintenance work.
Check regularly the condition of your laser device. Carry out main-
tenance work as a precautionary measure when you detect signs
of wear or dirt.
Check regularly the laser light cable 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 you

can come into contact with parts which are dangerous to
persons and things.
Improper or incautious procedures can cause injuries or
Danger damages to property.
Maintenance work may be carried out only by instructed per-
sons.
You must observe the warning instructions of these mainte-
nance instructions.
Before starting maintenance work, switch off the laser device.
Note
The laser device must be switched on during maintenance work
only if it is necessary for maintenance or control purposes. You will
be informed about this in the corresponding passages of this ma-
nual.
Help in case of problems Contact the service of TRUMPF Laser, if you have difficulties that
you can eliminate yourself. The service address is to be found at
the beginning of the operator's manual.

2. Material
2.1 Wearing parts
Recommended
Subassembly Designation Material no.
stock
Laser Pump module 1370988 1
Protective sleeve
Laser light cable with cover slide 1342948 1
for LLK-D
Deionizing filter,
Cooling unit 1329858 -
new
Deionizing filter,
1351629 1
reconditioned
Filter element in
1464769 1
the fine filter
Filter element in
1350346 1
the input filter
Filter cartridge in
the water sepa-
Air cleaner 0991071 1
rator + prelimi-
nary filter
Filter cartridge in
0991082 1
the submicro filter
Filter cartridge in
the active carbon 0991084 1
filter
Filter cartridge in
1426112 1
the intake filter
Filter mat in the
0991551 1
cabinet door
Electrics Fuse set 1352822 1
Tab. 5-1
20-05-15-A1-CR02 2008-01 Material 5-5

2.2 Tools and auxiliaries
Symbol Designation Dimensions, further specifications
Double-bit key for opening the doors and the hoods
Slotted screw driver 2,5 mm
Hexagon screwdriver 4 mm, 5 mm
Fork wrench 9 mm, 24 mm, 55 mm, 70 mm
Pan for cooling water
Cloth for wiping up spilled water
rubber, to be worn when handling

Safety gloves
deionized water
for cleaning the filter cartridge in the

Blow-out gun
entry filter
for unscrewing and attaching the ship-

Ratchet, Allen screw insert 10 mm
ping braces of the compressor
for protecting sensitive electronic com-

ESD wrist strap
ponents against electrostatic discharge
tools and material for cleaning work on

Cleaning set for optical components optical components
Material-No.: 0779603
Tools and auxiliaries for maintenance work Tab. 5-2
5-6 Material 2008-01 20-05-15-A1-CR02

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

low it.
Keep methanol away from fire and other ignition sources.
Caution Do not smoke.
Ensure sufficient fresh air supply.
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 passages.
Note
The instructions for disposal of waste material are recommenda-
tions, derived from regulations applied at place and time when
these operating instructions have been prepared. As operator of
the laser device, however, you are obliged to inform yourself about
the regulations concerning waste disposal and to observe these
regulations.
Unless the regulations applicable do no stipulate otherwise, the

waste material is to be disposed of as follows:
Protective sleeve with cover

Refuse
slide
Seals, O-Rings Refuse
Lens cleaning paper Refuse
Cooling water Sewerage system
Deionizing filter Have it refreshed at TRUMPF Laser
Filter material Refuse
Electric fuses Refuse
Tab. 5-3
20-05-15-A1-CR02 2008-01 Material 5-7

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

Danger
de-energized.
3.1 Opening and closing doors
2. 1. 1. 2.
Fig. 5-1
5-8 Opening and closing the laser device 2008-01 20-05-15-A1-CR02

3.2 Opening and closing the door to the
user room
1. 2.
3.
Fig. 5-2
20-05-15-A1-CR02 2008-01 Opening and closing the laser device 5-9

3.3 Opening and closing hoods
Fig. 5-3
5-10 Opening and closing the laser device 2008-01 20-05-15-A1-CR02

3.4 Removing side panel diode power
supply

Danger
de-energized.
Fig. 5-4
20-05-15-A1-CR02 2008-01 Opening and closing the laser device 5-11

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

2. After first making contact, push the hose into the coupling as
far as possible.
The hose is permanently connected to the hose coupling.
4.2 Disconnecting the hose
1.
2.
1.
Fig. 5-6
1. Press the hose coupling ring in direction of the hose coupling.

The hose coupling lock is unlocked.
2. Pull the hose out of the hose coupling.
5-12 Hose connections 2008-01 20-05-15-A1-CR02

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

nut retention.
1.
3.
2.
Fig. 5-7
20-05-15-A1-CR02 2008-01 Removing the securing device from the stop valve 5-13
6. Maintenance overview
Maintenance Maintenance
Maintenace work Section
spot interval
Pump module Replacing the pump module upon demand
Replacing the laser light cable upon demand (see "Removing LLK-D", pg. 5-30)
(see "Cleaning the protective sleeve
Laser light Cleaning the protective sleeve along with
upon demand along with the cover slide on the LLK-D",
cable the cover slide at the LLK-D
pg. 5-46)
Replacing the protective sleeve along (see "Replacing the protective sleeve
upon demand
with cover slide along with the cover slide", pg. 5-47)
(see "Topping up cooling water", pg.
Topping up cooling water upon demand
5-50)
(see "Replacing the water in the tank",
Replacing the water in the tank upon demand
pg. 5-63)
Cleaning the tank upon demand (see "Cleaning the tank", pg. 5-52)
(see "Replacing the deionizing filter", pg.
Replacing the deionizing filter upon demand
5-55)
(see "Cleaning the particle filter", pg.
Cleaning the particle filter upon demand
Laser cooler 5-58)
(see "Replacing filter element in the fine
Replacing filter element in the fine filter upon demand
filter", pg. 5-60)
Backfush the entry filter upon demand (see "Backfush the entry filter", pg. 5-65)
Clean the entry filter upon demand (see "Clean the entry filter", pg. 5-67)
(see "Check cooling block (Option)", pg.
Check cooling block (Option) anually
5-63)
(see "Emptying the cooling unit of the
Emptying and filling the cooling unit upon demand
laser device", pg. 5-71)
Replacing filter cartridge in the activated (see "Replacing filter cartridge in the
5000 h
carbon filter activated carbon filter", pg. 5-92)
(see "Replacing the filter cartridges in the
Replacing the filter cartridges in the
5000 h water separator and the submircofilter",
water separator and the submircofilter
pg. 5-95)
Air cleaner
Replacing the filter cartridge at the com- (see "Filter cartridge in the intake filter",
5000 h
pressor pg. 5-97)
(see "Completely replacing the air clea-
Completely replacing the air cleaner 10000 h
ner", pg. 5-98)
Replacing the filter fleece upon demand (see "Changing the filter mat", pg. 5-100)
(see "Activating an automatic circuit
Electrics Activating an automatic circuit breaker upon demand
breaker", pg. 5-103)
Changing a fuse upon demand (see "Changing a fuse ", pg. 5-104)
Replacing a microfuse upon demand (see "Replacing a microfuse", pg. 5-106)
Tab. 5-4
5-14 Maintenance overview 2008-01 20-05-15-A1-CR02

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

laser is assigned to each cavity of the laser device. Each pump unit
contains 4 pump modules than can be replaced individually.
Failure There are the following reasons for replacing pump modules:
A pump module has failed. In this case, a warning message
which indicates the failed pump module is displayed on the
operating PC.
Operation of the laser device cannot be continued unless you
changed the failed pump module.
A pump module releases insufficient pump light (e.g. power
reduction at the end of the service life).
This may be the case when a message is repeatedly dis-
played: “Excessive controller action”.
IIn this case, the operator, depending on his experience, de-
cides which pump module is to be replaced. It is also possible
that several pump modules must be replaced due to aging.
Special case: message due to failure of a pump module be-
cause of defective stack (see below).
Special case If a pump module failed due to a defective stack, and the pump
module bridging circuit is released:
A monitoring message indicates the impending maintenance
work.
The message text indicates which pump module failed.
In the main dialog down to the left a dialog "PM-bridging cir-
cuit“ with the following functions is displayed.
– Display of the remaining term (emergency operation), be-
ginning with 50 hours.
– Button „Acknowledge pump module failed“ for the ac-
knowledgement of the message.
20-05-15-A1-CR02 2008-01 Replacing the pump module 5-15

Fig. 5-8
In order to ensure that the user is informed about the operation
with pump module bridging, the remaining term is displayed per-
manently, until the laser device reports a fault. Only after acknowl-
edgement, the updated time remaining to the standstill of the laser
device is displayed. When the remaining term is expired after ac-
knowledgement, a further operation of the laser device is only pos-
sible, if the failed pump module was replaced.
Nach Ablauf der Restlaufzeit nach dem Quittieren ist ein weiterer
Betrieb des Lasergeräts erst möglich, wenn das ausgefallene
Pumpmodul ersetzt wurde.
If the failed pump module was replaced, the dialog „PM-bridging
circuit“ is automatically faded out, if the laser is switched on.
Assistance from service Contact the TRUMPF Laser Service Department if you are not sure
division which pump modules are to be replaced.
Qualification Pump modules may only be replaced by instructed persons. Con-
tact the TRUMPF Laser Service Department, if you need further
information on this.
Order You must proceed in the indicated order.
Work steps
Preparing the laser device
– Providing a spare pump module
– Identifying the pump module
Removing the pump module
Inserting the new pump module
– Taking the pump module out of the transport protection
– Inserting the new pump module
– Protecting the removed pump module
– Setting the address
Final procedures
– Check for impermeability
– Making the laser device ready for use
– Dewatering the pump module
– Packing the removed pump module.
5-16 Replacing the pump module 2008-01 20-05-15-A1-CR02

7.1 Preparing the laser device
Conditions
The laser device is connected to the mains, main switch in
position ON.
Compressed air is connected. (see chapter "Installation condi-
tions, transport").

Slotted screw driver, 2,5 mm
Preparing the laser device 1. Press OFF at the control panel.

2. Turn key-switch to the left.
Fig. 5-9
3. Open the lateral hood of the laser device.
Providing a spare pump

module
Fig. 5-10
4. Take the spare pump module out of the transport box for pump
modules.
5. Take the spare pump module out of packaging.
6. Put the pump module with transport protection on a clean sur-
face.

The pump module to be replaced can now be removed.
Identifying the pump module
A
1
9
A2
A3
DIAG A4
ERROR
Fig. 5-11
Note
If a pump module fails, the LED „Error" on this pump module
lights up.
A1
1
2 A2
A3
A4
1 Pump unit for cavity 1 2 Pump unit for cavity 2 The pump modules of each
pump unit are numbered:
A1, A2, A3, A4
Arrangement and numbering of the cavities, pump units and pump modules Fig. 5-12
7. Identify the pump module to be replaced.

7.2 Removing the pump module
Notes
An ESD wrist straps is located in the optical arrangement of
the laser device. It has a conductive contact with the device
frame.
Do not remove the pump module from the pump unit for a pe-
riod longer than necessary. Thus, work quickly and close the
beam guideway of the pump unit in case of interruptions.
The pump modules are sensitive to electrostatic discharge

(ESD)!
The pump modules can be destroyed: considerable damage
to property.
Caution
Wear a grounded ESD wrist strap when working on electrical
connections of the pump module.
Wear the ESD wrist strap directly on the skin.
The pump modules and pump unit contain sensitive optical

components!
If the optical components are soiled, it can cause damage to
the pump modules or the pump unit: considerable damage
Caution to property.
Handle the pump module in clean surroundings only.
Do not touch optical glass surfaces.
Avoid soiling of the pump unit.
1 Carrier plate 4 Lever

2 Pump module 5 Clamp
3 Locking device for lever
Fig. 5-13

1. With the right hand, hold the pump module to be replaced
alongside.
1.
2.
Fig. 5-14
2. With the thumbs of the left hand, press the locking device
downward and keep it pressed.
3. Press the lever carefully towards the pump module.
The clamp springs open.
2. 1.
Fig. 5-15

4. Press the pump module slightly towards the carrier plate.
5. Unhinge clamp.
Fig. 5-16
Note
It is possible that some water comes out during the next work-
ing step.
6. Lift the pump module to the right and pull it out carefully. Do
not touch optical surfaces and electric contacts.
7. Put the pump module on a clean surface.

7.3 Inserting the new pump module
Taking the pump module out

of the transport protection
3.
1.
2.
Put the pump module in the transport protection Fig. 5-17
1. Loosen the fastening screw.

2. Swing back the holding clamps.
3. Lift the pump module and pull it out towards the front.
4. Check the optical parts for cleanness, however make sure not
to touch them.
Inserting the new pump

module
2 1
1 Water connection 2 Slide in help
Fig. 5-18
5. Put the guide of the water connection (Pos. 1) in the groove of

the slide-in help (Pos. 2) and slide in the pump module as far
as possible.

2.
1.
Fig. 5-19
6. Press the pump module simultaneously
towards the laser and at the rear edge towards the carrier pla-
te.
7. Hang the clamp of the lever in the groove of the pump module.
The clamp can only be hanged, if the pump module is at the
correct stop position and is slightly pressed down.
8. Fix the pump module with the clamp.
Fig. 5-20
9. Push the lever outward with moderate
power.

Are optical components soiled despite all care?
You must not mount pump modules with soiled optical com-
ponents. The risk of failure is too high.
Inform the service of TRUMPF Laser.
Send the pump module to TRUMPF Laser.
Protecting the removed

pump module 1.
3.
2.
Put the pump module in the transport protection Fig. 5-21
10. Put the removed pump module in the transport protection.

11. Swing back the holding clamps.
12. Moderately tighten fastening screw.

Setting the address
Fig. 5-22
13. Set the address of the new pump module: the value corre-
sponds to the dismounted pump module.
The following table contains indications for setting the address:
Pump unit Pump module Address

A1 1
A2 2
1
A3 3
A4 4
A1 6
A2 7
2
A3 8
A4 9
Pump unit addresses Tab. 5-5
Now you can take off the ESD wrist strap.

7.4 Final procedures
Check for impermeability
Fig. 5-23
1. Check if the pump module at the stop is flush with the carrier
plate.
Pump botton Fig. 5-24
2. Briefly press the pump button in the optical arrangement sev-

eral times, then for a longer period.
Cooling water will flow through the pump units.
3. Check the connection of the replaced pump module for tight-
ness.
Making the laser device ready 4. Close the lateral hood.
for use 5. Turn key-switch to the right.
6. Press ON at the control panel.
The laser device is ready for use.

Dewatering the removed
pump module
Fig. 5-25
Loss of warranty in case of a not dewatered pump module!

If a dewatering is not done, the pump module may suffer
irreversible transport damage: considerable damage to pro-
perty.
Caution
Dewater the pump module.
7. Take out blow-out device.

8. Remove both plugs on the bottom of the transport protection.
9. Connect the hose of the blow-out device to the supply connec-
tion of the transport protection. If necessary, use one of the
adapters attached to the blow-out device.
10. Set the switch on the blow-out device in position 1 and do not
change its position for 2.5 minutes.
11. Set the switch on the blow-out device in position 0.
12. Remove the hose of the blow-out device.
13. Reinsert plugs on the bottom of the transport protection.
14. Stow the blow-out device in the laser device.

Packing the removed
pump module
Fig. 5-26
15. Pack the pump module with the transport protection and des-
iccant bags in the enclosed bag.
16. Seal the bag.
17. Put the bag in the transport case.
Here the pump module is protected against environmental ef-

fects and can be transported safely.

8. Removing and mounting the laser light
cable LLK-D
A laser light cable must be removed and fitted:

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

only.
ILN available If laser device exits are equipped with the Interface
LASERNETWORK (ILN) option, the following parts are additionally
mounted:
LLK coding cable with clamps
ILN box.
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
available”.
20-05-15-A1-CR02 2008-01 Removing and mounting the laser light cable LLK-D 5-29
8.1 Removing LLK-D
Work steps
Preparation.
Disconnect the LLK-D from the laser side.
Loosen the LLK-D from the focusing optics.
Remove and wind up the LLK-D.
Final procedures.
Condition
Compressed air is connected. (see chapter "Installation condi-
tions").

When replacing LLK-D, obtain information from TRUMPF La-
ser on the adequate number of new LLK-D, material depend-
ent on length.
Two protective caps per removed laser light cable.
Connectors for each coupling optical unit from which a laser
light cable is removed.
Plugs for all openings at the focusing optics from which the
laser light cables are removed.
Hexagon screwdriver, 5 mm.
Preparation
Fig. 5-27
1. Open the door to the user room.
5-30 Removing and mounting the laser light cable LLK-D 2008-01 20-05-15-A1-CR02
1 2 3 4
1 LLK-D 5 Bushings for further LLKs

2 LLK coding cable (option) 6 Screw
3 FO cable (option) 7 Holder
4 Field bus cable (option) 8 Slotted sleeves
Fig. 5-28
2. Remove the support on the bushing from the LLK-D to be re-

placed.
Now it is possible to disconnect the LLK-D from the laser side.
Disconnecting the LLK-D
from the laser side
1
2
4 5 6
1 FO cable 3 Field bus cable (green) 5 LLK coding cable

2 Clamps 4 Cooling water hoses 6 Monitoring plug
Incoupling optics with LLK-D Fig. 5-29
3. Withdraw monitoring plug (6).

4. Separate hose coupling of the cooling water hoses (4).
5. If the LLK-D is not supposed to be replaced but to be perma-
nently removed, additionally the following cables must be with-
drawn:
– FO cable(1)
– LLK coding cable(5)
– Field bus cable (3)
2.
1.
4. 3.
Fig. 5-30
6. Unscrew the securing connector.

7. Push the locking slider to the top.
Notes
Do not tilt or turn the optical plug.
Never touch the light guide end or the glass body of the
protective sleeve with fingers.
Avoid dirt on the plug or the light guide.
Do not knock the plug against anything. The light guide
might break.
8. Press safety ring in direction of the input optics and withdraw

the connector of the LLK-D.
Fig. 5-31
9. Put the protective cap on the LLK-D plug.
3.
4.
1.
2.
Fig. 5-32
10. Put the plug into the opening of the incoupling optics.
11. Push the locking slider downwards.
12. Screw in the locking connector.
ILN available Note

To avoid confusion the LLK-D and the LLK-coding cable must
always be laid together.
The LLK-D and the LLK-coding cable must be connected me-
chanically. For this TRUMPF Laser always supplies the cables
together with clamping pieces.
1
2
1 Clamp 2 Screw
Fig. 5-33
13. Screw out the screw (2) of the clamping
piece (1).
The LLK-D is disconnected from the laser side.
Loosen the LLK-D from the Note
focusing optics If the focusing optics is fitted on a swivelable mount, it should
be brought to a possibly horizontal position for the following ac-
tivities. So it is prevented that dirt gets to optical components
which are temporarily exposed when detaching the connec-
tions.
Fig. 5-34
14. Remove the cooling water hose leading to
the focusing optics.
1.
2. 3.
Fig. 5-35
15. Press down the saftey pin, press the sleeve towards the proc-
essing optics and remove the plug without canting or twisting it.
When canting the plug there is the risk that the cover silde is
damaged.
16. Place a protective cap on the plug of the LLK-D.
17. Place a plug in the opening of the processing optics.
18. Unscrew the screw of the clamping piece (only if ILN avail-
able).
The LLK-D is loosened from the focusing optics.
Remove and wind up the 19. Detach the LLK-D over its whole length from guidings, fasten-
LLK-D ing clamps, clamping pieces etc.
Note
When winding up, make sure that the optical plugs do not hit
anywhere. The light guide could be damaged.
20. Wind up the LLK-D in shape a ring of about 80 cm diameter.
Removal of the LLK-D is complete.
Dewatering the optical plugs

of the LLK-D 1
3
2
3
1 Closure coupling 3 Closure nipple

2 Close coupling with supply hose 4 Hose coupling
Fig. 5-36
Warranty loss in case of not dewatered optical plugs of the

LLK-D!
Neglect of dewatering can cause transport damage of the
LLK-D : material damage.
Caution
Dewater the optical plug of the LLK-D.
21. Take out blow-out device.

22. Put the closure couplings (1 and 2) to the closure nipples (3) of
the optical plugs.
23. Connect the hose of the blow-out device to the supply hose.
Tip
Use for the connection an appropriate connection piece. The
connection pieces are enclosed to the blow-out device.
If no suitable connection piece is availabe, the closure nipple of
the optical plug must be removed and be connected directly to
the blow-out device.
24. Turn the switch at the blow-out device to step I and keep it for
10 seconds in this position.
25. Turn the switch at the blow out device to stage 0.
26. Remove the hose of the blow-out device.
27. Remove the closure couplings (1 and 2) from the closure nip-
ples of the optical plugs (3).
Note
Both optical plugs of the LLK-D must be deaerated.
28. Stow the blow-out device in the laser device.
The optical plugs of the LLK-D are dewatered.
Removing the cooling

water hoses
Cooling water distributor LLK Fig. 5-37
29. If cooling water hoses shall be removed:

Withdraw cooling water hose from the cooling water distibutor
LLK-D.
If another LLk-D shall not be fitted immediately.
Final procedures 30. Make sure that protective caps or plugs are put on all resulting
openings.
31. Reattach the fixture of the lead-through at the laser device.
32. Close the door to the user room.
The removal of the LLK-D is finished.
8.2 Mounting the LLK-D
Work steps
Laying the LLK-D.
Connecting the LLK-D to the laser device.
Connecting the LLK-D to the focusing optics.
Final procedures.
Condition
Laser device is switched off and protected against restart.

Double-bit key
Hexagon screwdriver, 5 mm
Laying the LLK-D 1. The LLK-D connector is packed in protective shells. Do not
remove these protective shells, until you have laid the LLK-D.
Packaging Connector Use

Connection of the LLK-D to
Large Protective shell Incoupling connector
the laser device
Outcoupling connec- Connection of the LLK-D to
Small Protective shell
tor the processing optics
Tab. 5-6
2. Outside the laser cabin, laser light cables must be installed

permanently.
To do so, use:
– Cable clamps
– Cable ducts
– Other appropriate auxiliaries for fastening cables.
3. Inside laser cabins which are monitored by a safety circuit,
laser light cables can be laid freely and loosely.
To avoid mistakes 4. If an ILN is provided: Connect the LLK-D to the respective LLK
coding cable using clamps.
Note
Ensure that the LLK-D is installed without tensile stress, buck-
les and torsional strain. The bending radius must not be
smaller than 200 mm.
5. Install the LLK-D, the LLK coding cable (if available) and the
cooling water hoses by means of guides or mounting clips to-
wards the processing spot.
Fig. 5-38
6. Open the door to the user room.
Fig. 5-39
7. Remove the desired support from the
bushing.
2.
1.
4. 3.
Fig. 5-40
8. Remove plug from the opening of the
incoupling optics.
Connecting the LLK-D to the
laser device.
2
1
1 Protective shell 3 Protection foil

2 Seal
Fig. 5-41
9. Remove protective shell from the incou-
pling connector, break the seal and remove the protection foil.
Notes
Ensure that the openings from which the caps were re-
moved do not become soiled.
Fig. 5-42
10. Pull the protective cap from the incoupling connector.
1.
1.
2.
3.
4.
Fig. 5-43
11. Press the securing ring towards the incoupling optics and keep
it pressed during the inserting process. Insert the optical plug
as far as possible into the incoupling optics.
Note
It is absolutely necessary that the optical plug is inserted in the
incoupling optics as far as possible
12. Push the locking slide downward.

13. Plug in the securing connector and tighten it.
Connecting hoses and
connectors
3 4 5
Fig. 5-44
Note
Note Do not cant the cooling water hoses when connecting.
14. Connect the following cables and hoses:

– Monitoring plugto bushing A14x-101 (5).
– LLK coding cableto bushing A14x-225 (4).
– FO cableto bushing X225 (1).
– Field bus cable to bushing Profibus (2).
– Cooling water hoses (3).
–
Note
The clamp has to be max. 150 mm away from the plug of the
LLK coding cables.
1
2
1 Clamp 2 Screw
Fig. 5-45
15. Connect the LLK-D and the respective
LLK coding cable using the clamp (see Interface description
Interface LASERNETWORK).
The LLK-D is connected to the incoupling optics and the moni-
toring electronics.
Closing the LLK bushing at 1 2 3 4

the laser device
1 LLK-D 5 Bushings for further LLKs

2 LLK coding cable (option) 6 Screw
3 FO cable (option) 7 Holder
4 Field bus cable (option) 8 Slotted sleeves
Fig. 5-46
16. Insert the LLK-D and, if available, the LLK coding cable, FO
cable and field bus cable in the slotted sleeves (8).
17. Fasten the holder(7).
Connecting the LLK-D to the Note
focusing optics If the focusing optics is fitted on a swivelable mount, it should
be brought to a possibly horizontal position for the following ac-
tivities. So it is prevented that dirt gets to optical components
which are temporarily exposed when detaching the connec-
tions.
1.
2. 3.
Fig. 5-47
19. Press down the safety pin, press the
sleeve towards the processing optics and remove the protec-
tive cap of the focusing optics.
20. Remove protective shell from the optical plug, break the seal
and remove the protection foil.
Notes
Ensure that the openings from which the caps were re-
moved do not become soiled.
21. Remove the protective cap from the optical plug.
2. 1.
3. 4.
Fig. 5-48
22. Put the optical plug into the focusing op-
tics. When doing so put the optical plug into the groove of the
focusing optics
23. Press down the safety pin, push the sleeve into the direction of
the focusing optics and put the optical plug into the focusing
optics as far as possible.
24. Check if the optical plug latched correcty in the focusing optics
and cannot be pulled out any longer.
25. Check if the sleeve is tightly at the optical plug so that no soil
can enter.
ILN available 26. Connect the LLK-D to the respective LLK coding cable using
clamps.
Note
The clamp has to be as close as possible to the plug of the
LLK coding cable, in any case it has to be in the laser protec-
tive enclosure. More information can be found in the Test pro-
cedure “Interface LASERNETWORK LLK coding cable”, which
is enclosed with each LLK coding cable.
27. Check connection (see Interface description "Interface

LASERNETWORK (ILN)").
Connecting the cooling

water hoses
2
1 Supply hose 2 Return hose
Fig. 5-49
28. Connect the supply hose (1) to the focusing optics.

29. Connect the return hose (2) to the connector.
The LLK-D is now connected to the focusing optics.
Final procedures 30. Check newly established cooling water connections for leaks:
– in the connection room LLK.
– at the focusing optics.
The LLK-D and the respective LLK coding cable, in case that ILN is
available, are installed.
9. Maintaining laser light cable
9.1 Cleaning the protective sleeve along

with the cover slide on the LLK-D

Lens cleaning paper and methanol from the optics cleaning set
(Material-Nr. 0779603).
Notes
Never touch the cover slide with the fingers.
Ensure that the cover slide is not scratched.
Methanol is inflammable and toxic when you inhale or swal-

low it.
Keep methanol away from fire and other ignition sources.
Caution Do not smoke.
Ensure sufficient fresh air supply.
Do not inhale methanol vapor.
Cleaning the cover slide
1
2
1 Protection sleeve 2 Cover slide
Fig. 5-50
1. Moisten the lens cleaning paper with methanol.

2. Slowly wipe across the cover slide until it is clean.
Note
If the cover slide exhibits scratches or burnt-in particles, the
protective sleeve along with the cover slide must be replaced,
(see "Replacing the protective sleeve along with the cover sli-
de", pg. 5-47).
3. Used lens cleaning paper must be disposed of as refuse.
5-46 Maintaining laser light cable 2008-01 20-05-15-A1-CR02

9.2 Replacing the protective sleeve along
with the cover slide

Protective sleeve with cover slide for LLK-D (Material-Nr.
1342948).
Cleaning set for optical components (Material-Nr. 0779603).
Notes
Never touch the optical wave guide (2).
Ensure that the optical wave guide is neither soiled nor dam-
aged.
With the protection sleeve (3) removed, hold the opening of the
LLK-plug downward so that no dirt particles can fall on the end
of the wave guide.
Do not touch the cover slide of the new protective sleeve.
Make sure that no dirt particles enter the new protective
sleeve.
4
5
1 2
1 Optical plug of the LLK-D 3 Protective sleeve with cover slide 5 Mounting key
2 Light guide 4 Protecting cap 6 Notch
Replacing the protective sleeve along with the cover slide Fig. 5-51
20-05-15-A1-CR02 2008-01 Maintaining laser light cable 5-47

Removing defective protec-
tive sleeve along with cover
slide
Fig. 5-52
1. Screw off the protection sleeve along with cover slide using the
notch on the mounting key as screw driver.
Note
If you remove the protective sleeve laterally, there is a risk that
wave guide becomes damaged.
2. Remove the protective sleeve cautiously from the optical plug.
Mounting a new protective

sleeve along with the cover
slide
Fig. 5-53
3. Remove protective cap from the mounting key.

4. Fasten new protective sleeve with the mounting key.
5. Check new cover slide for soiling and clean it, if neces-
sary,(see "Cleaning the protective sleeve along with the cover
slide on the LLK-D", pg. 5-46).
6. Ensure appropriate disposal of the mounting key and the old
protective sleeve.
5-48 Maintaining laser light cable 2008-01 20-05-15-A1-CR02

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

Topping up cooling water.
Changing the cooling water.
Cleaning the tank.
Replacing the deionizing filter.
Cleaning the particle filter.
Replacing the fine filter.
Backfush the entry filter.
Clean the entry filter.
Check cooling block (Option).
1 Tank 3 Stop valve in the return 5 Deionizing filter

2 Backflushable entry filter 4 Fine filter
Laser cooler Fig. 5-54
20-05-15-A1-CR02 2008-01 Laser cooler 5-49

10.1 Topping up cooling water
Cooling water must be topped up if:

a message is displayed which indicates that the water level in
the tank is too low.
the deionization filter was replaced
the fine filter was replaced.
Condition
Control unit of laser device is switched off.

Deionized water
Conductivity < 5 µS, recommended: ca. 3 µS
Protective gloves for protection against DI water
Use deionized water (DI water) as cooling water!

DI water may affect skin and textiles.
Avoid any contact of DI water with eyes, nose or mouth.
Caution Avoid any contact of DI water with your clothing.
You can wash away DI water with tap water.
Wear work gloves.
5-50 Laser cooler 2008-01 20-05-15-A1-CR02

PPAA__00
PA 111
_0
PA_01
Topping up cooling water Fig. 5-55
1. Open the front door to the laser cooler.

2. Loosen the quick coupling on the tank and remove the cover.
Note
The 100 % mark is located in the inside of the tank.
3. Top up with DI water until the water level reaches the 100 %
mark.
4. Close the tank cover.
5. Close the front door to the laser cooler.
20-05-15-A1-CR02 2008-01 Laser cooler 5-51

10.2 Cleaning the tank
If deposits are visible, it may be necessary to clean the tank of the

laser cooler.
Condition

Fork wrench 9 mm
Tap water as a cleaning agent.
Cleaning cloth.
Deionized water ca. 90 l.
When required: Fine filter and tools necessary for replacing the
fine filter (see "Replacing filter element in the fine filter", pg.
5-60).
Pan with ca. 90 l capacity
or
Drain in the floor.

Wear work gloves.
5-52 Laser cooler 2008-01 20-05-15-A1-CR02

Preparation
PAA
P_A
0_1
_0011
PA_01
Fig. 5-57

2. Place the collecting pan on the floor in front of the laser device.
3. Take blue hose out of the holder.
4. Place the end of the hose in the collecting pan and open the
stop valve.
The DI water in the tank drains off.
5. Pour the water that ran out into the sewerage.
6. Close the stop valve on the blue hose and hang the hose in its
support.
Cleaning the tank 7. Clean the inside of the tank with clean tap water and a cloth.
Do not use cleaning additives.
8. Dry the inside of the tank.
Filling the tank 9. Fill the tank up to the MAX-marking with water (see "Topping
up cooling water", pg. 5-50).
20-05-15-A1-CR02 2008-01 Laser cooler 5-53

Ventilating the pump
9 mm
PA_01
Vent screw Fig. 5-58
Note
To ensure correct functioning of the DI water pump, it must be
ventilated prior to the startup of the laser device.
11. Loosen the vent screw on the pump head. When water leaks,
close the vent screw.
5-54 Laser cooler 2008-01 20-05-15-A1-CR02

10.3 Replacing the deionizing filter
The conductivity of the cooling water in the laser cooling circuit will
be adjusted to a value within the range of 2.5 µS ..3,5 µS. A moni-
toring or fault message is displayed when the value is above this
range. In this case replace the deionizing filter during the next
standstill period of the laser device.
The laser device switches off when a conductivity of 8 µS is rea-
ched for the cooling water. You cannot operate the laser device
when the conductivity is higher than 8 µS.
Condition

Absorbent cloth.
Bucket or deep washbasin
Deionized water, ca. 1,5 l
New deionizing filter, material No. (see "Wearing parts", pg.
5-5).
or
refreshed deionizing filter, material No. (see "Wearing parts",
pg. 5-5).
Note
If the cooling water is cloudy instead of clear, the cooling water has
to be changed as well .
Preparing the laser device 1. Open the front door to the laser cooler.

Wear work gloves.
20-05-15-A1-CR02 2008-01 Laser cooler 5-55

Removing the deionizing
filter
1
2
1 Stop valve for the supply hose 4 Hose coupling for the return
hose
2 Stop valve for the return hose 5 Fastening screw
3 Hose coupling for the supply
hose
Fig. 5-59
2. Close the stop valves in the supply hose (1) and return hose
(2).
3. Disconnect the hose couplings in the supply hose (3) and re-
turn hose (4).
4. Wipe off drained DI water with a clean cloth.
5. Loosen the fastening screw (5) and take the deionization filter
out of the support.
6. Put the deionization filter with the connections showing down-
ward into a bucket for about 30 minutes, to allow the DI water
to drain off completely.
Mounting a new deionizing 7. Insert new deionization filter and connect it.
filter 8. Open the stop valves in the supply and return hoses of the
deionization filter.
Check for impermeability 9. Turn main switch of the laser device to the ON position.
10. Turn on control unit on the control panel.
11. Check the tightness of the hose coupling on the replaced de-
ionization filter.
Note
The 100 % mark is located in the inside of the tank.
5-56 Laser cooler 2008-01 20-05-15-A1-CR02

PPAA
P_A
0
_0
_1
011
PA_01
13. Top up with DI water until the water level reaches the 100 %
mark.
20-05-15-A1-CR02 2008-01 Laser cooler 5-57

10.4 Cleaning the particle filter
The particle filter is connected downstream from the deionization

filter and prevents granulates from the deionization filter from en-
tering the cooling circuit of the laser.
Clean the particle filter, if:

a message indicates that the conductivity of the DI water has
exceeded the permissible limit.
the soiling of the filter is visually recognizable.
Condition

Cleaning cloth for wiping leaked cooling water.

Wear work gloves.
Position of the particle filter Fig. 5-61
5-58 Laser cooler 2008-01 20-05-15-A1-CR02

Cleaning the particle filter
1 Filter element 2 Filter cap
Fig. 5-62
2. Unscrew the filter cap and take out the filter element.
3. Rinse the filter element with water.
4. Check the filter element for:
– damage.
– any soiling still left.
5. Either
Insert the cleaned filter element if it is neither damaged nor
soiled.
or
Insert the cleaned filter element if it is neither damaged nor
soiled.
6. Tighten the filter cap by hand.
9. Open the front hood.
10. Press the pump button in the optical arrangement for approx.
10 seconds and check if water leaks out from the filter cap.
11. If necessary, tighten the filter cap.
13. Close the front hood.
20-05-15-A1-CR02 2008-01 Laser cooler 5-59

10.5 Replacing filter element in the fine filter
A filter element in a fine filter has to be changed if a message ap-

pears stating that the pressure drop in a fine filter is too large.
Condition

Filter spanner.
Disposal gloves for protection of the filter element.
Absorbent cloth.
Filter element, (see "Material ", pg. 5-5).
Note
Make sure the filter element is not contaminated. The protective
film the new filter element must be opened immediately before
insertion into the filter. The filter element must only be deposited on
an absolutely clean surface.
Replacing the filter element
Fig. 5-64
5-60 Laser cooler 2008-01 20-05-15-A1-CR02

Wear work gloves.
2. Loosen filter cup with the filter spanner.
1 Filter support 3 Filter cup

2 Filter element
Fig. 5-65
3. Remove the filter cup along with the filter
element.
4. Carefully take the filter element (2) out of the filter cup (3) and
let it dry in an appropriate vessel.
Fig. 5-66
5. Wipe off drained cooling water with a
clean cloth.
6. Put on the disposal gloves to protect the new filter element
against germs.
20-05-15-A1-CR02 2008-01 Laser cooler 5-61

7. Open the protective film of the new filter element and insert the
new filter element.
8. Remount the fine filter in reverse order.
Water enters the fine filter.
11. Check tightness of the fine filter.
If the fine filter is leaky, check seat and condition of the O ring.
In case of damage or wear, replace the O-ring.
Final procedures 12. Check the DI water level in the tank. If necessary, fill in DI
wa-ter until the 100 % mark (see "Topping up cooling water",
pg. 5-50).
5-62 Laser cooler 2008-01 20-05-15-A1-CR02

10.6 Replacing the water in the tank
A prolonged exposure of the cooling water to light may cause an

algae growth in the tank, if, for example, the front door of the laser
device remains open for a longer period and the tank cover is re-
moved. Therefore keep the doors and the tank closed if no work is
to be carried out inside the laser device.
Only replace the cooling water, if it is no longer clear but dim.
Emptying the tank
Condition

Deionized water, ca. 90 l
Pan
or
Drain in the floor.
When required: Fine filter and tools necessary for replacing the
fine filter(see "Cleaning the particle filter", pg. 5-58)

Wear work gloves.
20-05-15-A1-CR02 2008-01 Laser cooler 5-63

PAA
P_A
0_1
_0011
PA_01
Fig. 5-56

3. Take blue hose out of the holder.
4. Place the end of the hose in the collecting pan and open the
stop valve.
The DI water in the tank drains off.
5. If necessary, clean the tank (see "Cleaning the tank", pg.
5-52).
Replacing filter elements 6. If a message appears stating that the pressure drop in a fine
filter is too large: Replace the filter element in the fine filter (see
"Cleaning the particle filter", pg. 5-58).
Disposal 7. The water can be disposed of in the sewerage system.
Filling in cooling water
Fill in fresh DI water in the tank until the 100 % mark (see
"Topping up cooling water", pg. 5-50).
5-64 Laser cooler 2008-01 20-05-15-A1-CR02

10.7 Maintaining the entry filter
The entry filter separates particles from the water in the supply of
the external circuit.
The entry filter can be maintained by:

backflushing.
cleaning or replacing the filter insert.
Backfush the entry filter
The entry filter must be backfushed, if:

a pressure too high at the filter is reported.
soiling can be recognized visually.
Condition

Pan
or
Drain in the floor.
20-05-15-A1-CR02 2008-01 Laser cooler 5-65

PPAA
P_A
0
_0
_1
011
PA_01
Fig. 5-67
2. Place the collecting pan on the floor in front of the laser

device.
3. Remove the blue hose below the backflush valve and put it into
the collecting pan.
4. Open the backflush valve about 15 seconds (turning knob
ver-tical). Dirt is flushed out of the filter.
5. Stow the blue hose in the laser device and close the door of
the laser cooler.
5-66 Laser cooler 2008-01 20-05-15-A1-CR02

Clean the entry filter
The entry filter must be cleaned, if WinLas reports too high a dif-
ferential pressure at the filter.
Condition

Filter spanner.
Hexagon screwdriver, 4 mm.
Blow-out gunfor compressed air.
Absorbent cloth.
upon demand: Filter element.
upon demand: O-ring for fine filter.
Pan
or
Drain in the floor.
Preparation
Fig. 5-68
1. Close stop valves of the external cooling circuit.

2. Open the door to the laser cooler.
20-05-15-A1-CR02 2008-01 Laser cooler 5-67

PPAA
P_A
0
_0
_1
011
PA_01
Fig. 5-69
3. Place the collecting pan on the floor in
front of the laser device.
4. Take out the blue hose below the backflush valve and put it
into the collect pan.
5. Open the backflush valve (turning knop vertical).
The water pours out of the entry filter.
Removing holding angle
Fig. 5-70
7. Unscrew the fastening screws.

8. Remove holding angle.
5-68 Laser cooler 2008-01 20-05-15-A1-CR02

Cleaning filter insert
1 Filter casing 5 Filter cup

2 Filter element 6 Wrench for filter cup (Accesso-
ries in the chiller)
3 Spring 7 Backflush valve
4 O-ring
Fig. 5-71
9. Loosen filter cup with filter wrench (6).
Note
The filter wrench is already fastened at the filter cup and pro-
tected against falling down by means of a velcro fastener.
10. Remove filter cup (5)and pay attention to O-ring (4).

11. Lift the filter element (2)out of the filter cup.
12. Wash the filter element with tap water and blow it off by means
of compressed air.
13. If the filter element is damaged, replace the damaged filter
element by a new one.
14. Wash the filter cup by means of tap water.
15. Put the filter element with spring (3)) into the filter cup.
16. Put O-Ring (4) on filter cup.
17. Put the filter cup on the filter casing and tighten it.
18. Close back flushing valve (7)(turning knop horizontal).
19. Open the stop valve of the external cooling circuit.
20. Check the entry filter for tightness. If leaky, retighten the filter
cup, replace the O-ring if required.
21. Reattach holding angle.
22. Stow the blue hose in the laser device and close the door of
the laser cooler.
20-05-15-A1-CR02 2008-01 Laser cooler 5-69

10.8 Check cooling block (Option)
Condition

Double-bit key
1. Open the door to the cooling block.

2. Check all connections and stop valves for tightness.
3. In case of leaks, inform the service of TRUMPF Laser.
5-70 Laser cooler 2008-01 20-05-15-A1-CR02

10.9 Emptying and filling the cooling unit
Emptying the cooling unit of the laser de-

vice
All tanks and hoses, filled with water while operating the laser de-
vice, must be emptied completely in the following situations:
before transport or storage of the laser device at low tempera-
tures (danger of frost)
in case of transport by aircraft
before a long shutdown of the laser device (several weeks).
Conditions
Compressed air is connected.(see chapter "Installation condi-
tions").

Panfor collecting the cooling water
Cloth to wipe up drained off cooling water
Strap wrench
Fork wrench 24 mm, 70 mm
Note
It is advantageous to have a drain in the floor near the laser device
through which the water runs into the sewerage system. If not, you
will need a suitable collecting pan.
20-05-15-A1-CR02 2008-01 Laser cooler 5-71

Emptying the external 1. Close the hose water connections (if available) in the supply
cooling circuit and return of the external circuit. The stop valves at the laser
device stays open.
2. Either
Place the tub in front of the drain hoses on the floor.
or
Hang the drain hoses into the sewerage.
Fig. 5-72
3. Open the stop valves of the drain hoses.
The cooling water runs out.
70 mm
Fig. 5-73
4. When no water runs out any longer:

Remove the cooling water hoses.
Keep the stop valves of the cooling water hoses also open du-
ring the next steps.
5-72 Laser cooler 2008-01 20-05-15-A1-CR02

Emptying the cooling block Note
(Option) The cooling block is an optional component of your laser de-
vice. If your laser device is not equipped with a cooling block,
continue immediately with the work step "Emptying the stop
valve to the cooling block".
5. Open the door to the cooling block.

6. Place a collect pan before the cooling block on the floor.

Wear work gloves.
Fig. 5-74
7. Open stop valve.
About 10 l DI water run out of the stop valve.
20-05-15-A1-CR02 2008-01 Laser cooler 5-73

2.
1.
Fig. 5-75
9. Loosen screwing above tank and lift it
slightly so that air can enter into the cooling circuit.
10. Retighten the screwing above the tank.
11. When no water runs out any longer:
Close the stop valve in the cooling block.
Fig. 5-76
12. Open stop valves.
5-74 Laser cooler 2008-01 20-05-15-A1-CR02

Water flows into the casing socket and escapes from the drain
hose of the casing socket.
Fig. 5-77
13. If no more water runs out of the stop valves:

Close again the stop valves at the cooling block.
Empty the stop valve to the Note

cooling block If your laser device is equipped with an optional cooling block,
then the line to the cooling block is connected at this stop
val-ve. In this case keep the stop valve opened and continue
im-mediately with the work step "Empty input filter".

15. Keep cloth or vessel ready for collecting cooling water which is
running out.
2. 1.
Fig. 5-78
16. Remove cap.
17. Open stop cock.
Cooling water runs out.
Note
Keep the stop valve opened also during the next steps.
20-05-15-A1-CR02 2008-01 Laser cooler 5-75

Emptying the entry filter
PPAA
P_A
0
_0
_1
011
PA_01
Fig. 5-79
19. Remove the blue hose below the backflush valve and put it into
the collecting pan.
20. Open the reversible flow valve (turning knop vertical).
The cooling water in the reversible flow valve runs out.
21. The drained-off water can be disposed of in the sewerage
system.
22. Close reversible-flow valve and stow the hose.
5-76 Laser cooler 2008-01 20-05-15-A1-CR02

Emptying the solenoid valve Note
Cooling water that flowed to the casing socket escapes at the
water drain hose of the socket from the casing.
Fig. 5-80
23. Open the stop valves under the solenoid valve.
Fig. 5-81
Cooling water flows out of the drain hoses
into the casing socket.
Note
If your laser device is equipped with an optional cooling block,
then the line to the cooling block is connected to this stop
val-ve. In this case keep the stop valve opened.
20-05-15-A1-CR02 2008-01 Laser cooler 5-77

Fig. 5-82
24. If no more cooling water runs out of the
drain hoses:
Close stop valves under the solenoid valve again.
25. Fit the cap.
Fig. 5-83
26. Shut the stop valves (4x).
27. The drained-off water can be disposed of in the sewerage
system.
5-78 Laser cooler 2008-01 20-05-15-A1-CR02

Dewater the laser circuit
PPA_A
PA0_10
_0 11
PA _01
Fig. 5-84

Wear work gloves.
29. Take the hoses out the holders.
30. Lay the ends of the hose into the but and open the stop valves.
The DI-water in the tank and in the tube system runs out.
Note
Go on keeping the hoses in the tub.
20-05-15-A1-CR02 2008-01 Laser cooler 5-79

Emptying the pump
PA _01
Fig. 5-85
31. Remove the screw from the foot of the
pump.
The remaining DI-water runs out of the pump.
32. If no more DI-water runs out of the pump:Screw in the screw
again.
Empty cooling water dis-

tri-butor OPTICS
Fig. 5-86
33. Remove the plug at each end of the dis-
tribution tubes.
Air gets into the cooling circuits. The DI-water flows into the
tank of the laser cooler.
Note
Do not plug again the plugs immediately, they are not plugged
until the final steps of the work.
5-80 Laser cooler 2008-01 20-05-15-A1-CR02

Emptying the deionization
filter
1
2
1 Stop valve for the supply hose 4 Hose coupling for the return
hose
2 Stop valve for the return hose 5 Fastening screw
3 Hose coupling for the supply-
hose
Fig. 5-87
34. Close the stop valves in the supply hose (1) and return hose
(2).
35. Disconnect the hose couplings in the supply hose (3) and re-
turn hose (4).
36. Loosen the fastening screw (5) and take the deionization filter
out of the support.
38. Put the deionization filter with the connections showing down-
ward into a bucket for about 30 minutes, to allow the DI water
to drain off completely.
20-05-15-A1-CR02 2008-01 Laser cooler 5-81

Emptying the particle filter 1
2 3
1 Particlefilter 3 Stop valve in the return

2 Stop valve in the supply
Fig. 5-88
39. Open the stop valves in the return (3) and
the supply (2).
Fig. 5-89
41. Remove the filter cap of the particle filter.
42. Pour out the water remaining in the filter cap.
43. In case of soiling, rinse the filter element with water.
44. Tighten the filter cap by hand.
5-82 Laser cooler 2008-01 20-05-15-A1-CR02

Emptying the fine filter
Fig. 5-90
45. Loosen filter cup with the filter spanner.
Note
Leave the filter element in the filter cap and do not touch it with
bare fingers.
Fig. 5-91
47. Mount the filter cap.

46. Pour out the water remaining in the filter cap.
20-05-15-A1-CR02 2008-01 Laser cooler 5-83

Blowing out cooling lines in
the optical arrangement
Fig. 5-92
48. Open the lateral hood and the hood on
the rear side of the laser device.
49. Open the left door on the rear side of the laser device and re-
move the blow-out unit.
Note
In the optical zone there are 3 cooling water distributors (ar-
rows). In order to dewater all cooling lines in the optical zone, it
is required to dewater all supply cooling lines at the 3 cooling
water distributors.
Fig. 5-93
50. Pull out one of the blue hoses at one of
the cooling water dis-tributors.
51. Connect the hose of the blow-out device with the blue hose.
52. Turn the switch of the blow-out device to stage 1 and leave it
2,5 minutes in this position.
5-84 Laser cooler 2008-01 20-05-15-A1-CR02

The DI water from the cooling line is pressed into the tank of
the laser cooler. Flow noises are audible.
53. Turn the switch of the blow-out device to stage 0.

54. Separate the hose of the circuit which was blown out from the
hose of the blow-out device and put it again into the hose
cou-pling of the cooling water distributor.
55. In the 3 cooling water distributors, blow out all blue hoses one
after the other according to the same method except for the
two large ones.
The cooling lines in the optics zone are dewatered.
Detwater diode power 56. Open the front door to cooling control.
sup-plies and CLC-box
Fig. 5-94
57. At the upper cooling water distributor, 4
blow out hoses at the upper side and the hose on the left side
of the cooling water distributor, as described with the previous
work steps.
The cooling lines to the diode power supply are dewatered.
20-05-15-A1-CR02 2008-01 Laser cooler 5-85

Final procedures 58. Put in the deionizing filter again and connect it.
Fig. 5-95
59. Attach the plug at the cooling water dis-
tributor OPTICS.
PPA_A
PA0_10
_0 11
PA_01
Fig. 5-96
60. Close the stop valves and hang hoses
again into the holders.
61. The water can be disposed of in the sewerage system.
The laser device is now completely emptied.
5-86 Laser cooler 2008-01 20-05-15-A1-CR02

Filling the cooling unit
Conditions
The laser device has to be connected to the power supply
system.
External cooling water lines are connected

Deionized water, ca. 95 l
Fork wrench, 9 mm
Preparation 1. Open the front door to the laser cooler.

2. Open the hoods.
Checking connections
1 2
4 5 6 10
7
8 7
10
3
11
1 Hose connections on the dis- 5 Stop valves magnetic filter 9 Fine filter
tributor
2 Plug on the cooling water dis- 6 Stop valve in the return 10 Stop valves laser circuit
tributor to the focusing optics
3 Drain hoses 7 Connections on the deionization 11 Screw on pump foot
filter
4 Stop valve before closure cou- 8 Stop valve chiller
pling
Fig. 5-97
Note
All connections were separated when emptying the laser de-
vice. Therefore all connections that had been separated must
be checked before filling the cooling.
3. Check if the connections are completely and correctly con-
nected/closed.
20-05-15-A1-CR02 2008-01 Laser cooler 5-87

Filling the laser circuit
PPAA
P_A
0
_0
_1
011
PA_01
Note
The MAX mark is located in the inside of the tank.
5. Top up with DI water until the water level reaches the MAX
mark.
Ventilating the pump

9 mm
PA_01
Vent screw Fig. 5-99
6. Loosen the vent screw on the pump head. When water leaks,
close the vent screw.
5-88 Laser cooler 2008-01 20-05-15-A1-CR02


9. Briefly press the pump button in the optical arrangement sev-
eral times, then for a longer period.
DI water flows into the fine filter and through the pump units.
10. Check the connections for leaks.
Topping up DI water Note

The water level in the tank has sunk due to the filling of the fine
filters and the pump units. If the water level is below the 100
%-mark, DI water must be refilled.
11. Fill up DI-water until the water level reaches the 100 % mark.
14. Close the hoods.
Filling the external circuit
Fig. 5-101
15. Open the housewater connections in the
supply and the return of the external circuit.
16. Open the stop valve of the external cooling circuit.
Water flows into the external circuit.
The internal and external circuits are filled.
20-05-15-A1-CR02 2008-01 Laser cooler 5-89

11. Maintenance of the air cleaner
Fig. 5-102
1 intake filter 3 submicro filter

2 water separator + preliminary 4 active carbon filter
filter
Air cleaner, controller swivelled out Fig. 5-103
5-90 Maintenance of the air cleaner 2008-01 20-05-15-A1-CR02

Maintenance intervals Some wear parts must be replaced in stipulated maintenance in-
tervals (operating hours).
Spare part Material no. Maintenance interval

Filter cartridge in water separa-
0991071 5.000 h
tor + preliminary filter
Filter cartridge in submicro filter 0991082 5.000 h
Filter cartridge in active carbon
0991084 5.000 h
filter
Filter cartridge in intake filter 1426112 5.000 h
Filter mat in the cabinet door 0991551 5.000 h
Air cleaner, complete 0568024 10.000 h
Tab. 5-7
Note
If the intake filter at the compressor and in the cabinet door must
be replaced earlier in dusty environment, this is indicated by a mo-
nitoring message on the screen of the operating PC.
20-05-15-A1-CR02 2008-01 Maintenance of the air cleaner 5-91

11.1 Replacing filter cartridge in the acti-
vated carbon filter
Condition

Filter cartridge for activated carbon filter(Fastened at the frame
of the air cleaner).
Preparation
Fig. 5-104
1. Open the door to the air cleaner.
2. Controller swiveled out.

Replacing filter cartridge
3.
1.
2.
Fig. 5-105
3. Lift the filter casing and turn it to the left.

4. Pull filter casing downward.
5. Unscrew filter cartridge.
6. Screw in new filter cartridge and close the filter casing in the
reverse order.

Enter the serial number in the 7. Switch on the laser device.
maintenance assistant 8. Start program WinLas.
9. Select WinLas-menu >Diagnostics Maintenance.
Maintenance database is opened.
10. Click on tab "Assistent".
Maintenance assistant is displayed.
Fig. 5-106
11. Enter the own name (1).
Note
The serial number in engraved in the floor of the bottom of the
filter cartridge.
12. Enter the serial number (10-digits) of the replaced filter car-
tridge (2).
Note
The serial number is printed on the packaging of the filter car-
tridge.
13. Enter the serial number of the new filter cartridge (3).
14. Click onAcknowldege quit(4).
The maintenance assistant is closed.
15. Click on Cancel.
Maintenance data base is closed.

11.2 Replacing the filter cartridges in the
water separator and the submircofilter
The subsequently described work steps are the same for:

water separator + preliminary filter
submicro filter
Condition

Filter cartridge for water separator + preliminary filter (Material
no. 0991071).
Filter cartridge for submicro filter (Material no. 0991082).
Preparation
Fig. 5-107
2. Controller swiveled out.

Replacing filter cartridge
6.
4.
3.
2. 5
1.
Fig. 5-108
3. Remove the condenate drain hose.

4. Screw out the screw at the plug and remove the plug.
5. Lift the filter casing and turn it to the left.
6. Pull the filter casing to the bottom.
7. Unscrew filter cartridge.
8. Screw in filter cartridge and close the filter casing in the re-
verse order.

11.3 Filter cartridge in the intake filter
Condition

Hexagon screwdriver, 4 mm
Fork wrench, 19 mm
Filter cartridge for intake filter, (Material no. 1426112).
1.
3.
4 mm
19 mm
2.
Fig. 5-109
2. Loosen the screws at the protection grid (3x) and remove pro-
tection grid.
3. Loosen the cap nuts of the connection line (2x) and remove
connection line.
4. Unscrew filter lid.
5. Unscrew the filter cartridge from the filter lid.
6. Screw the new filter cartridge into the filter lid.
7. Fit the connection line and protection grid again.

11.4 Completely replacing the air cleaner
The complete air cleaner has to be replaced, if, after correct main-
tenance of the air cleaner, a malfunction occurs repeatedly after
reset that does not refer to replacement of filter cartridges or filter
mats.
Condition

Hexagon screwdriver, 4 mm, 5 mm
Air cleaner, (Material no. 0568024).
The compressor of the air cleaner can be hot immediately

after operation.
Risk of burns on the hands.
Caution Wait until the compressor has cooled down.
Fig. 5-110
Note
Before changing the air cleaner, please take use of the diag-
nosis tools offered by the TRUMPF Laser service staff. The
TRUMPF Laser service staff has access to your laser device
with the tele-presence option (if provided) and can make a di-
agnosis based on the available data.
1. The data of the air cleaner can be indicated by means of the

WinLas menu >Measurement > Air cleaner.

Removing the air cleaner
2 5
1 Connection for intake hose 3 Fixation: Screw + fixation 5 Fixation for condensate drain
hose
2 Connection for clean air hose 4 Fixation: Screws at the holding
angle
Fig. 5-111
2. Loosen all connectors on the right side of the air cleaner.

3. Remove the suction hose.
4. Remove the clean air hose.
5. Remove condensate drain hose.
6. Loosen the screw (pos 3) and remove the front part of the
support.
7. Loosen screws (pos. 4) and remove the holding bracket.
8. Take the air cleaner out of the laser device.
9. Mount the shipping brace (see chapter "Installation conditions,
transport").
Installing a new air cleaner 10. Install the new air cleaner in reverse order.
11. Remove the shipping brace before commissioning (see chap-
ter "Installation conditions, transport").

11.5 Changing the filter mat

Filter mat (Material no. 0991551 ).
1 2
1 Air entry 3 Diaphragm

2 Filter mat
Fig. 5-112
1. Take off the diaphragm.
2. Take out the filter mat.
3. Insert a new filter mat.
4. Reattach the cover plate.

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

chang-ing fuses or switching on the automatic circuit breakers
when they are disconnected due to a malfunction.
A blown fuse has to be changed. A circuit breaker that has become
disconnected must be switched on again. This is indicated by the
failure of partial functions or through corresponding messages on
user’s interface.
12.1 Identifying blown electrical fuses
Conditions
The laser device has to be connected to the power supply
system.
The mains switch of the laser device must be in position ON
(EIN).

Danger
Before touching electric parts, first check if they are de-
energized.
Fig. 5-113
1. Opening the doors to the power supply

You obtain access to the mains distribution.
20-05-15-A1-CR02 2008-01 Electrics 5-101

1 2 1
1 Automatic circuit breaker 2 Fuses 3 Microfuses
The mains distribution Fig. 5-114
2. Identify the blown automatic circuit breaker.

A blown automatic circuit breaker can be identified by the
green display above the black lever of the circuit breaker.
3. Determine a burnt-out fuse.
You can identify a blown fuse by the lighting of a glow lamp
which is located in the fuse holder.
4. Determine a burnt-out microfuse.
You can identify a blown microfuse by the non-lighting of a
glow lamp which is located above the fuse.
In the following sections you will learn about: Activating automatic

circuit breakers, Changing burnt-out fuses, Replacing microfuses.
5-102 Electrics 2008-01 20-05-15-A1-CR02

12.2 Activating an automatic circuit breaker
Conditions
The blown automatic circuit breaker must be identified (see
"Identifying blown electrical fuses ", pg. 5-101).

Circuit breakers may be switched on only while the device is
turned off.
Danger
Fig. 5-115
1. Eliminate the cause of the automatic circuit breaker blowing.

Otherwise, it may occur that it will blow again as soon as the
device is switched on.
2. Move the black lever of the blown automatic circuit breaker
upwards.
The color of the display changes from green to red.
3. Close doors.
20-05-15-A1-CR02 2008-01 Electrics 5-103

12.3 Changing a fuse
Conditions
The blown fuse has to be identified (see "Identifying blown
electrical fuses ", pg. 5-101).
When the doors are open during operation, there is danger

of coming in contact with live electrical parts!
The laser must be switched off when fuses are changed.
Danger
3 1
1 Fuse 3 Flap of the fuse holder

2 Glow lamp (3x)
Fig. 5-116
Note
The replacement fuse must have correct current and fusing
properties. A list with the values of the fuses is attached to the
inside of the door to the mains distribution.
1. Open the flap of the fuse holder.
2. Pull the blown fuse out of the holder.
3. Replace the blown fuse with a new fuse of the same type (cur-
rent and fusing properties).
5-104 Electrics 2008-01 20-05-15-A1-CR02

4. Close the flap of the fuse holder.
5. Eliminate the cause of the fuse blowing. Otherwise, it may
occur that the replaced fuse will blow again when the device is
switched back on.
6. Close doors.
Disposal 7. Ensure an appropriate disposal of the blown fuse.
20-05-15-A1-CR02 2008-01 Electrics 5-105

12.4 Replacing a microfuse
Conditions
The blown microfuse has to be identified (see "Identifying
blown electrical fuses ", pg. 5-101).

Fuses must be changed only with the device turned off.
Danger Any work on the electric equipment must be carried out only
1 Catch 4 Transparent cover, open

2 Contact springs 5 Retaining spring
3 Rod 6 Fuse
Fuse holder Fig. 5-117
1. Pull out the fuse holder with the blown fuse.
Note
Do not use any tools to extract the fuse!
2. Open the transparent cover of the fuse holder. Do this by pres-
sing the latch (1) towards the case of the fuse holder.
3. Push the rod (3) upward.
The fuse is ejected.
5-106 Electrics 2008-01 20-05-15-A1-CR02

1 Clamp 2 Fuse
Fig. 5-118
Note
The replacement fuse must have correct current and fusing
properties. A list with the values of the fuses is attached to the
inside of the door to the mains distribution.
4. Insert a new fuse and make sure it is in a symmetrical position

(see "Fig. 5-118", pg. 5-107) (left).
The fuse must be inserted in such a way that the clamps take
hold of both metal caps of the fuse.
Do not use any sharp-edged tools to correct the position.
5. Close the transparent cover.
6. Eliminate the cause of the fuse blowing. Otherwise, it may
occur that the replaced fuse will blow again when the device is
switched back on.
7. Insert the fuse holder in the mains distribution very carefully.
8. Close doors.
Disposal 9. Ensure an appropriate disposal of the blown microfuse.
20-05-15-A1-CR02 2008-01 Electrics 5-107

5-108 Electrics 2008-01 20-05-15-A1-CR02
Chapter 6
Conduct in case of service

interruptions
1. Service interruptions..................................................... 6-2

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

3.1 Monitoring ........................................................................ 6-4
3.2 Fault ................................................................................. 6-6
4. Dealing with messages ................................................. 6-7

4.1 Structure of a message.................................................... 6-7
4.2 Message memory ............................................................ 6-9
Message memory ....................................................... 6-9
Message filter ........................................................... 6-10
Displaying the message text..................................... 6-11
Head of the table ...................................................... 6-11
Type of message ...................................................... 6-11
20-05-15-A1-CR02 2008-01 Conduct in case of service interruptions 6-1

1. Service interruptions
TRUMPF Laser laser devices are equipped with extensive monito-

ring 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 interrup-

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

2. Carry out recommended measures according to the instructi-
ons of the manual, if applicable.
If you cannot identify or eliminate the cause of service inter-

ruptions:
Number of the message that is displayed on the monitor of the
operating PC.
the events which caused the service interruption.
The service of TRUMPF Laser will carry out all necessary work in
order to allow you to operate the laser device as soon as possible.
6-2 Service interruptions 2008-01 20-05-15-A1-CR02

2. Identifying causes
Different factors outside and inside the laser device can be taken
into consideration as causes for service interruptions. Before taking
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 processing optics.
Errors in programs:
– Pulse shapes.
– laser programs.
– Light paths.
– Sequential programs in external control units (PLC etc).
Error in wiring of interfaces in case of external control of the
laser device.
Maloperation.
Malfunctions in the laser device.
Having identified the cause, take appropriate measures to elimina-

te it. Please contact the Service Department of TRUMPF Laser if
you need assistance.
20-05-15-A1-CR02 2008-01 Identifying causes 6-3

3. Monitoring and faults
3.1 Monitoring
Numerous operational values of the laser device are monitored.
Examples:
Laser power.
Position of the switch mirrors and shutter mirrors.
Temperature and flow of the cooling water.
The operational values are constantly measured and compared to

nominal values or limit values. If an operational value is outside the
permissible range, the control unit of the laser device generates a
monitoring message.
Monitoring message
1 Reporting subassembly 4 Short message text

2 "Monitoring" sign 5 Status indicator ”Monitoring"
3 Number of the message
Monitoring message is displayed Fig. 6-1
Items 1, 3 and 4 are indicated in yellow.
Reporting subassembly Subassembly (board) of the control unit that generates the mes-
sage.
"Monitoring" sign This sign indicates a monitoring message even if the status indica-
tor is covered by a dialog field. Color: blue.
Number of the message The number corresponds to the message code which is transmit-
ted from the control unit to the operating PC. The message text
can be displayed at any time by entering this number in the dialog
box ”Search message text".
6-4 Monitoring and faults 2008-01 20-05-15-A1-CR02

”Diagnosis" menu Fig. 6-2
Select >Diagnosis >Search message text.
Short message text The short text gives the operator one-line information on the cause
of the message.
Status indicator “Monitoring” The status indicator "Monitoring" lights up in red if a monitoring
message is displayed.
Note
When a monitoring is displayed you can still operate the laser de-
vice. You should eliminate the cause at the next opportunity. If you
do not remedy the cause, it may be possible that a monitored ope-
rational value exceeds the fault limit in the near future (see section
Fault).
In case of a fault you can only continue to operate the laser device,
when the cause is eliminated..
20-05-15-A1-CR02 2008-01 Monitoring and faults 6-5

3.2 Fault
When a monitored operational value is far outside the permissible

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

the laser is deactivated automatically.
a fault message is displayed on the screen.
Fault message
1 Reporting subassembly 5 Short message text

2 ”Fault" sign 6 Status indicator ”Fault"
3 "Monitoring" sign 7 Status indicator ”Monitoring"
4 Number of the message
A fault message is displayed Fig. 6-3
Items 1, 4 and 5 are indicated in red.

In addition to a fault message(see "Fig. 6-1", pg. 6-4) the following
is indicated if a fault occurs:
”Fault" sign This sign indicates a fault message even if the status indicator is
covered by a dialog field.
Status indicator ”Fault" In addition to the status indicator ”Monitoring", the status indicator
"Fault" lights up in red if a fault message is displayed.
Note
In case of malfunction, the laser device cannot be operated until
the cause of the malfunction has been eliminated and the laser
device has been reset. For more information on this, please refer
to the section “How to respond to messages” in chapter "Operati-
on".
6-6 Monitoring and faults 2008-01 20-05-15-A1-CR02

4. Dealing with messages
4.1 Structure of a message
Displaying a message text
Display of a message Fig. 6-4
In order to display the full message text: ? click on it.
The following display will be shown on the screen:
1 Short text 5 Text ”Effect" 8 Reporting subassembly

2 Message type 6 Text ”Cause" 9 Button ”Next cause"
3 Number of the message 7 Text ”Measure" 10 Scroll bar
4 Button ”Previous cause"
Structure of a message Fig. 6-5
20-05-15-A1-CR02 2008-01 Dealing with messages 6-7

Short text
The short text is identical to the message line on the WinLas
main screen (see Fig. 6-3).
Message type:
The following displays are possible here:
· Monitoring message
· Fault message
· Light-path-Fault message
· Light-path-Monitoring message
· Maintenance message
· Information
Button ”Previous cause"

If several causes of a reported effect are possible: a mouse
click on this button shows the preceding cause.
Text ”Effect"
This describes how the reported condition manifests itself.
Text ”Cause"
An effect may have several causes. One of these causes is in-
dicated in this area. All the causes can be displayed in succes-
sion by means of buttons (4) and (9). The number of causes is
indicated in the text header ”Cause" (in the example: 7).
Text ”Measure"
A specific measure belongs to each cause. Cause and the per-
tinent measure are always displayed together.
Reporting subassembly
Here it is indicated which subassembly of the laser device the
message comes from (in the example: Cooling unit).
6-8 Dealing with messages 2008-01 20-05-15-A1-CR02

Button ”Next cause"
If several causes of a reported effect are possible: A mouse
click on this button shows the next cause.
Scroll bar
Use the scroll bar to scroll the message text vertically if it is too
long to be displayed in the display window.
4.2 Message memory
All messages are entered in a message stack so that they can still
be read even after resetting the laser device. This function is useful
for diagnostic purposes.
Message memory
”Diagnosis" menu and Button List (arrow) Fig. 6-6
Select >Diagnosis >View all laser messages.

or
click List.
The contents of the message stack are displayed.

1 Message filter 3 Message texts
2 Table head 4 Message types
Contents of the message stack Fig. 6-7
Message filter
The messages in the message stack can be filtered according to

category. In this case, only the messages of the marked category
will be displayed.
Fig. 6-8
Check the symbol of the category whose messages are to be

displayed in the message stack.

Displaying the message text
In order to display the full message text:

Double click on list entry.
Head of the table
1 Symbol for the message type 3 8-digit message number 5 Short message text
2 Consecutive number 4 Date and time when the messa-
ge appeared
Fig. 6-9
The head of the table contains the column titles.
Type of message
For each message, the corresponding symbol is displayed in the

message stack.
The categories are marked with symbols.
Symbol Category Meaning

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

Information
laser device changed.)
A change in configuration has been
Logbook made (for example, a laser program
has been transmitted).
Notes are only output in the message
Note
line. (for example, Please wait!)
Tab. 6-1


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Operator's manual

The insulation resistance is the resistance which is measured at an

The equipment is disconnected from the mains during transport.

According to EN 60204, the insulation resistance must be ≥ 1 MΩ.

TRUMPF laser devices can have an insulation resistance < 1 MΩ

1. Look for the minimal insulation resistance admissible for the

Address for orders TRUMPF Laser GmbH + Co. KG

Address for service TRUMPF Laser GmbH + Co. KG

This document was compiled by the Technical Documentation Dept. of

© TRUMPF Laser GmbH + Co. KG

TRUMPF Laser GmbH + Co. KG cannot be held responsible for possible

Operation The operating instructions are to be found in chapter 4The ele-

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

20-05-15-A1-CR02 2008-01 Before you proceed ... 5

1. General notes................................................................. 1-2

2. Information on special risks ......................................... 1-5

3. Warning instructions in this manual ......................... 1-14

4. Designated use of the laser device............................ 1-16

5. Laser beam exit ports.................................................. 1-17

6. Location and function of the safety devices............. 1-18

6 Table of contents 2008-01 20-05-15-A1-CR02

7. Labels and warning signs........................................... 1-23

Chapter 2 Installation conditions, transport

2. Dimensions .................................................................... 2-4

3. Weight, floor at the installation site........................... 2-10

4. Connections ................................................................. 2-11

5. Electrical connected loads ......................................... 2-17

6. Cooling unit .................................................................. 2-19

7. Ambient conditions ..................................................... 2-26

20-05-15-A1-CR02 2008-01 Table of contents 7

10. Position of the user ..................................................... 2-28

11. First measures to be taken after receipt of the

12. Transport ...................................................................... 2-33

2. Laser ............................................................................... 3-3

3. Optical arrangement...................................................... 3-4

8 Table of contents 2008-01 20-05-15-A1-CR02

5. Laser light cable (LLK-D) ............................................ 3-16

6. Focusing optics ........................................................... 3-18

7. Control .......................................................................... 3-20

8. The mains distribution ................................................ 3-22

9. Laser cooler ................................................................. 3-24

10. Cooling block (Option) ................................................ 3-27

11. Cabinet cooler.............................................................. 3-28

12. Air cleaner .................................................................... 3-30

13. Diode current supplies................................................ 3-32

14. Blow-out device ........................................................... 3-32

15. Operating-PC................................................................ 3-33

16. Control panel................................................................ 3-35

17. WinLas program .......................................................... 3-36

18. Telepresence................................................................ 3-47

20-05-15-A1-CR02 2008-01 Table of contents 9

1. Operating elements and indicators ............................. 4-2

2. Switching the laser device on and off ......................... 4-7

3. Operating laser device with WinLas .......................... 4-10

4. Controlling the laser device externally...................... 4-25

10 Table of contents 2008-01 20-05-15-A1-CR02

2. Material ........................................................................... 5-5

3. Opening and closing the laser device ......................... 5-9

4. Hose connections........................................................ 5-13

5. Removing the securing device from the stop

6. Maintenance overview................................................. 5-15

7. Replacing the pump module....................................... 5-16

8. Removing and mounting the laser light cable