Trupunch 5000

Operator's manual
TruPunch 5000
Operator's manual
TruPunch 5000
Original operator's manual

Edition: 2008-11-01
Ordering information Please specify the following when ordering this document:
Operator's manual
TruPunch 5000
Edition 2008-11-01
Document number B380
Ordering address TRUMPF Werkzeugmaschinen GmbH + Co. KG

Technische Dokumentation
Johann-Maus-Straße 2
D-71254 Ditzingen
Tel.: +49 7156 303 - 0
Fax: +49 7156 303 - 30540
Internet: http://www.trumpf.com
E-Mail: docu.tw@de.trumpf.com
For "partly completed machinery" in accordance with the EC Machinery

Directive, this document corresponds to the assembly instructions.
© TRUMPF Werkzeugmaschinen GmbH + Co. KG

Contents
Chapter 1 Safety
1. For your safety............................................................... 1-3
2. Terminology ................................................................... 1-4
3. Operational safety ......................................................... 1-5

3.1 Intended use of the system.............................................. 1-5
3.2 Measures to be taken by the user/operator..................... 1-7
Danger signs and warnings ........................................ 1-7
Symbols ...................................................................... 1-7
Signaling words .......................................................... 1-8
Information on the source and type and how
to avoid the danger..................................................... 1-8
Instructing personnel .................................................. 1-9
Duty of care when handling the system ..................... 1-9
Eliminating malfunctions during operation................ 1-12
Using designated spare parts and
operating materials ................................................... 1-12
Water protection ....................................................... 1-13
3.3 Measures taken by the manufacturer ............................ 1-14
Securing of the danger zone of the system.............. 1-14
4. Laser safety.................................................................. 1-16
5. Danger due to magnetic fields ................................... 1-17
6. Overview of residual risks .......................................... 1-18
0-6 Contents B380EN00_OHNE FELDF.DOC

Chapter 2 TruPunch 5000 Installation Conditions
Responsibilities.......................................................................... 2-3
1. Planning aid ................................................................... 2-4
2. Installation site............................................................... 2-6

2.1 Space requirements......................................................... 2-6
2.2 Floor requirements........................................................... 2-6
2.3 Load indications............................................................... 2-8
2.4 Ambient conditions ........................................................ 2-11
2.5 Air purity......................................................................... 2-11
3. Electrical supply .......................................................... 2-12

3.1 Power supply ................................................................. 2-12
Isolating transformer................................................. 2-13
3.2 Connected loads/fuse protection ................................... 2-15
3.3 Remote diagnostics ....................................................... 2-15
3.4 Network connection ....................................................... 2-16
4. Compressed air supply ............................................... 2-17
5. Operating materials ..................................................... 2-20

5.1 Operating materials for the hydraulic system ................ 2-20
5.2 Cooling water for the cooling unit .................................. 2-21
5.3 Materials ........................................................................ 2-21
5.4 Pallets for SheetMaster (optional) ................................. 2-23
5.5 Older tool cartridges ...................................................... 2-23
5.6 New MultiTools and tapping tools.................................. 2-25
6. Transport ...................................................................... 2-26

6.1 Measures to be taken by the customer ......................... 2-27
Machine delivery....................................................... 2-27
Unloading the machine from the truck...................... 2-28
Transporting the machine to the installation site ...... 2-31
Installing the machine............................................... 2-32
B380EN00_OHNE FELDF.DOC Contents 0-7

Chapter 3 Description
1. The machine concept .................................................... 3-4
2. Technical data................................................................ 3-7
3. The most important assemblies................................... 3-8

3.1 Machine frame ................................................................. 3-9
3.2 Punching head............................................................... 3-10
3.3 Coordinate guide with linear magazine ......................... 3-11
3.4 Drives............................................................................. 3-12
3.5 Part removal .................................................................. 3-13
4. Tools ............................................................................. 3-14

4.1 The tool system ............................................................. 3-14
4.2 Components of a tool set............................................... 3-16
Punch........................................................................ 3-16
Punch selection ........................................................ 3-18
Alignment ring........................................................... 3-20
Die ............................................................................ 3-20
Stripper ..................................................................... 3-22
4.3 Stripper selection ........................................................... 3-23
Table 1: Short, flat punch ......................................... 3-26
Table 2: Long, flat punch .......................................... 3-27
Continuation of table 2.............................................. 3-28
Table 3: Angle-sheared punch ................................. 3-29
Stripper selection examples ..................................... 3-30
4.4 Tool innovations............................................................. 3-33
Roller tools................................................................ 3-33
Roller deburring tool and deburring MultiTool .......... 3-35
TRUMPF MultiTools ................................................. 3-36
Tapping tools ............................................................ 3-41
Clean cutting with TRUMPF MultiShear................... 3-43
Press brake bending with the
TRUMPF MultiBend.................................................. 3-44
Quick beading........................................................... 3-45
Engraving.................................................................. 3-45
Adaptive stroke calibration ....................................... 3-46
5. Maximum output tables............................................... 3-48

5.1 Calculation formulae ...................................................... 3-48
5.2 Influencing factors.......................................................... 3-49
5.3 Punch............................................................................. 3-51
5.4 Dies................................................................................ 3-51
5.5 Table overview............................................................... 3-53

6. Stroke rate tables......................................................... 3-56
6.2 Table overview: TruPunch 5000 (medium format) ........ 3-57
Standard tool ............................................................ 3-57
Whisper tool.............................................................. 3-59
Standard tool with active presser foot ...................... 3-60
Long standard tool with active presser foot.............. 3-61
MultiTool ................................................................... 3-62
Forming tool.............................................................. 3-63
6.3 Table overview: TruPunch 5000 (large format) ............. 3-64
Standard tool ............................................................ 3-64
Whisper tool.............................................................. 3-66
MultiTool ................................................................... 3-69
Forming tool.............................................................. 3-70
7. Technical information: Automation ........................... 3-71

7.1 Automation made to measure ....................................... 3-71
7.2 Overview of automation ................................................. 3-72
7.3 Simple automation ......................................................... 3-73
SheetMaster ............................................................. 3-74
Loading table (TruPunch 5000 only) ........................ 3-78
GripMaster ................................................................ 3-79
ShearMaster (not TruPunch 3000) ........................... 3-81
7.4 Flexible manufacturing cell ............................................ 3-83
ToolMaster (only TruPunch 3000 and
TruMatic 6000).......................................................... 3-84
Cart systems with travel rails.................................... 3-87
Cart system with toothed belt drive .......................... 3-89
Characteristic features.............................................. 3-90
SortMaster Box ......................................................... 3-91
SortMaster Pallet ...................................................... 3-92
7.5 Flexible manufacturing cell with TRUMPF
compact store ................................................................ 3-94
7.6 Flexible sheet machining system................................... 3-96
7.7 Control system and administration for connection
to storage ....................................................................... 3-97
8. Control system technology ........................................ 3-98
9. Programming ............................................................. 3-100

9.1 Directly at the machine ................................................ 3-100
9.2 In the office .................................................................. 3-101
Defining machining: What is done
automatically?......................................................... 3-102

10. The most important options ..................................... 3-103
10.1 Active die ..................................................................... 3-104
10.2 Die spray lubrication .................................................... 3-105
10.3 Brush tables with loading and unloading aid ............... 3-106
10.4 Height-adjustable clamps ............................................ 3-107
Chapter 4 Operation
Part 1: Control elements ........................................................... 4-7
1. Control elements: Overview ......................................... 4-7
2. Control panel with color display .................................. 4-9

2.1 Operating elements of the machine............................... 4-10
2.2 Operating elements of the control system ..................... 4-14
3. Keyboard ...................................................................... 4-18
4. USB connection ........................................................... 4-19
Part 2: User interface............................................................... 4-20
1. Structure of the user interface ................................... 4-20

1.1 Menu bar........................................................................ 4-21
1.2 Status line ...................................................................... 4-21
1.3 Message bar .................................................................. 4-22
1.4 Softkey bar..................................................................... 4-22
1.5 Display area................................................................... 4-22
2. Machine submodes ..................................................... 4-23

2.1 AUTOMATIC submode.................................................. 4-23
2.2 MDA submode ............................................................... 4-24
2.3 JOG submode................................................................ 4-24
3. Control areas................................................................ 4-25
4. Diagnostics .................................................................. 4-26
5. PRODUCTION Operation............................................. 4-27

5.1 PRODUCTION Single job.............................................. 4-27
Layout of graphics .................................................... 4-27

5.2 PRODUCTION Production plan .................................... 4-30
5.3 NC program management in the NCU .......................... 4-32
5.4 PRODUCING machine components ............................. 4-33
5.5 PRODUCTION Program options ................................... 4-34
5.6 PRODUCTION Switch elements ................................... 4-35
Operating the switch elements ................................. 4-35
General switch elements .......................................... 4-36
Z axis calibration (optional)....................................... 4-38
Switch elements H+L diagnostics page 1................. 4-39
SortMaster Box switch elements (optional) .............. 4-40
GripMaster switch elements (optional) ..................... 4-40
SheetMaster axis switch elements (optional) ........... 4-40
SheetMaster General switch elements (optional)..... 4-41
5.7 PRODUCTION: Tables.................................................. 4-42
Loading sheets ......................................................... 4-43
Sheet unloading........................................................ 4-46
Sheet technology...................................................... 4-54
Workpiece removal................................................... 4-55
Repositioning ............................................................ 4-60
Tool technology – Tapping (optional) ....................... 4-61
Tool technology – Engraving (optional).................... 4-62
Tool technology – Punching/general ........................ 4-64
Tool technology – Quick beading (optional) ............. 4-67
Tool technology – Multishear (optional) ................... 4-67
Tool technology – Roller tool (optional).................... 4-69
6. SETUP Operation......................................................... 4-72

6.1 SET-UP Switch elements .............................................. 4-72
Punching switch elements ........................................ 4-73
SortMaster Box switch elements (optional) .............. 4-74
Support table switch elements (optional) ................. 4-75
SheetMaster switch elements (optional) .................. 4-76
Stripper unit switch elements (optional) ................... 4-77
ToolMaster switch element (optional)....................... 4-77
Loading table switch elements (optional) ................. 4-78

6.2 SET UP Jog mode ......................................................... 4-79
6.3 MDA SET-UP................................................................. 4-80
7. PROGRAMMING Operation......................................... 4-81

7.1 NC Editor ....................................................................... 4-81
7.2 PROGRAMMING NC program management ................ 4-81
7.3 PROGRAMMING File management.............................. 4-83
7.4 Sending NC programs from the program manager ....... 4-86
8. TOOLING Operation .................................................... 4-87

8.1 TOOLING Tool table (autom.) ....................................... 4-87
8.2 TOOLING Tool table (manual) ...................................... 4-87
Setting up rails .......................................................... 4-87
Setting up the ToolMaster (optional) ........................ 4-87
Set up rail/tool (optional)........................................... 4-89
8.3 Selecting NC programs.................................................. 4-90
8.4 TOOLING Rail allocation ............................................... 4-91
8.5 TOOLING tool allocation................................................ 4-91
8.6 TOOLING Tools............................................................. 4-93
Required tools........................................................... 4-93
Tool change list......................................................... 4-93
General tool data ...................................................... 4-94
Tool master data/status data .................................... 4-95
8.7 Explanation of the tool data ........................................... 4-97
9. MAINTENANCE/START-UP Operation..................... 4-102

9.1 Maintenance/start-up Data backup.............................. 4-102
Changing the configuration for a partial backup..... 4-104
Starting a partial backup manually ......................... 4-104
Starting a complete backup .................................... 4-105
9.2 MAINTENANCE/START-UP Display........................... 4-105
10. DIAGNOSTICS Operation.......................................... 4-106

10.1 DIAGNOSTICS Fault diagnostics................................ 4-106
10.2 DIAGNOSTICS I/O diagnostics ................................... 4-107
10.3 DIAGNOSTICS Remote diagnostics ........................... 4-107
10.4 DIAGNOSTICS Display original position ..................... 4-108
11. Integrated MDR Operation (optional)....................... 4-109

11.1 MDR Message text ...................................................... 4-109
11.2 MDR Creating and modifying message texts .............. 4-110
11.3 MDR Displaying and editing machine data.................. 4-112
11.4 MDR Creating and changing interruptions .................. 4-114
11.5 MDR Evaluating machine data .................................... 4-115
11.6 MDR Displaying the times in list form.......................... 4-116
11.7 MDR Changing the time .............................................. 4-116

Part 3: Operating the machine.............................................. 4-117
1. Switching the machine on and off ........................... 4-118

1.1 Switching on the machine............................................ 4-118
1.2 Switching off the machine in the event of
malfunctions or emergencies....................................... 4-119
1.3 Switching off the machine............................................ 4-119
2. Executing a program ................................................. 4-120

2.1 Executing a program automatically ............................. 4-120
2.2 Executing a program with the softpunch (optional) ..... 4-121
2.3 Triggering a single stroke ............................................ 4-122
2.4 Changing the forming depth ........................................ 4-123
2.5 Program stop during execution.................................... 4-124
2.6 Stopping programs ...................................................... 4-124
2.7 Reentry into a program ................................................ 4-125
3. Working with the production plan ........................... 4-127

3.1 Creating a production plan........................................... 4-127
3.2 Executing a production plan ........................................ 4-128
3.3 Restarting the execution of the production plan
after a program interruption ......................................... 4-129
4. Moving the axes manually ........................................ 4-130
5. Releasing the drive brakes ....................................... 4-131

5.1 Releasing the X and Y axis drive brakes..................... 4-131
6. Manual execution of the lubrication cycle .............. 4-132
7. Diagnostic functions ................................................. 4-133

7.1 Fault diagnostics.......................................................... 4-133
7.2 Displaying machine inputs and outputs ....................... 4-134
7.3 Remote diagnosis via pcANYWHERE......................... 4-135
7.4 Querying the software version ..................................... 4-135
8. Managing master files ............................................... 4-136

8.1 Uploading NC programs from the USB interface ........ 4-136
8.2 Uploading NC programs from the hard disk ................ 4-137
8.3 Output of NC programs via USB ainterface................. 4-138
8.4 NC program output on the hard disk drive................... 4-139
8.5 Program part output via USB interface........................ 4-140
8.6 Deleting NC programs from the program manager ..... 4-141

9. NC program management......................................... 4-142
9.1 Displaying NC text ....................................................... 4-142
9.2 Editing NC text............................................................. 4-143
Searching for a block in the NC text....................... 4-143
Searching for a function in the NC text................... 4-144
Searching for and replacing a function in the
NC text.................................................................... 4-144
Inserting an additional line...................................... 4-146
Copying and inserting text passages ..................... 4-147
Deleting text passages ........................................... 4-148
10. Editing tables based on NC text............................... 4-148
11. TOOLING..................................................................... 4-150

11.1 Creating an automatic tool table and loading the
tool rail ......................................................................... 4-150
11.2 Manually loading/unloading tools ................................ 4-151
11.3 Loading a tool from the rail onto the ToolMaster
(optional) ...................................................................... 4-152
11.3 Correcting clamp positions .......................................... 4-153
11.4 Removing an active tool .............................................. 4-154
11.5 Unloading all tools ....................................................... 4-154
12. Operating the integrated MDR.................................. 4-154

12.1 Creating a message text.............................................. 4-155
12.2 Assigning a message text............................................ 4-155
12.3 Splitting up an interruption period................................ 4-156
12.4 Evaluating machine data ............................................. 4-157
13. Adjusting the pressure foot pressure ..................... 4-158
14. If problems arise ........................................................ 4-159

14.1 Removing stripper from stripper adapter ..................... 4-159
14.2 Removing the punch from the punching head............. 4-161
14.3 Removing the die from the die holder.......................... 4-164
14.4 Replacing the stripper segment................................... 4-165
15. Using ShearMaster (optional)................................... 4-166

15.1 Starting and stopping ShearMaster manually.............. 4-166
15.2 Change scrap container............................................... 4-167
15.3 Use ShearMaster in stacking mode............................. 4-167
15.4 Technical notes............................................................ 4-168
15.5 Correcting malfunctions ............................................... 4-168
Release tilted scrap skeleton.................................. 4-168
Release tilted scrap from the chute........................ 4-169

16. Using height-adjustable clamps .............................. 4-170
16.1 Moving height-adjustable clamps ................................ 4-170
16.2 Utilizing height-adjustable clamps ............................... 4-171
16.3 Help if problem arises ................................................. 4-171
Chapter 5 Maintenance of the machine
1. General guidelines......................................................... 5-4
2. Maintenance overview................................................... 5-5
3. Lubrication ..................................................................... 5-8

3.1 Overview .......................................................................... 5-8
3.2 Maintenance instructions ............................................... 5-11
Longitudinal and transverse guides.......................... 5-11
Transverse carrier and table support bearings......... 5-13
Central lubrication..................................................... 5-14
Hydraulics ................................................................. 5-15
Zero stop sensor (only TruPunch 5000
with automation) ....................................................... 5-20
Punch spray lubrication ............................................ 5-21
Die spray lubrication (optional) ................................. 5-24
Tapping lubrication unit (optional) ............................ 5-26
Die clamping piston clamp........................................ 5-30
Rail transverse carrier and table support ................. 5-31
Punch holder............................................................. 5-32
Active die (optional) .................................................. 5-32
4. Hydraulic system ......................................................... 5-34

4.1 Overview ........................................................................ 5-34
4.2 Depressurizing the accumulator system........................ 5-35
Hydraulic accumulator .............................................. 5-37
Hydraulics hose lines................................................ 5-41
Hydraulic unit ............................................................ 5-43
5. Pneumatic system ....................................................... 5-46

5.1 Overview ........................................................................ 5-46
Air cushions (optional) .............................................. 5-47

6. Mechanical elements................................................... 5-50
6.1 Overview ........................................................................ 5-50
Punching tool adapter............................................... 5-51
Chip vacuum system: side channel blower .............. 5-52
Chip vacuum system: vacuum pipe.......................... 5-54
Chip vacuum system: chip flap................................. 5-55
Chip vacuum system, complete................................ 5-57
Tool cartridge support slat ........................................ 5-59
Clamps...................................................................... 5-60
Racks and guide rails ............................................... 5-61
Index pin(s) ............................................................... 5-61
Brush field segment tables, parts flap and brush
tables (optional) ........................................................ 5-62
Brush field segment tables ....................................... 5-64
Compressed air maintenance unit............................ 5-67
Control panel ............................................................ 5-68
7. Electrics ........................................................................ 5-69

7.1 Overview ........................................................................ 5-69
Switch cabinet: connectors and clamping screw
connections............................................................... 5-70
Switch cabinet: external air circuit ............................ 5-70
Switch cabinet: NCU battery..................................... 5-71
Buffer battery box PC ............................................... 5-73
Safety light barrier and light barrier parts flap
(optional)................................................................... 5-76
Inductive proximity switch......................................... 5-77
Sensor system - stripper sensor............................... 5-78
8. Cooling unit.................................................................. 5-82

9. Procedure after a collision ......................................... 5-87
10. Handling the setting device ........................................ 5-88

10.1 Assigning the punch and alignment ring........................ 5-88
10.2 Determining the tool length............................................ 5-90
11. Regrinding tools .......................................................... 5-91

11.1 Compensating the regrind amount ................................ 5-92

Chapter 6 Maintenance of the automation

2.1 SheetMaster and GripMaster
maintenance overview ..................................................... 6-6
2.2 ToolMaster maintenance overview (40/70) ..................... 6-7
2.3 SortMaster Box maintenance overview ........................... 6-7
2.4 SortMaster Pallet maintenance overview ........................ 6-7
2.5 Maintenance overview Double cart with guide rails......... 6-8
2.6 Maintenance overview for double cart with toothed
belt drive .......................................................................... 6-9
2.7 ShearMaster maintenance overview ............................... 6-9
3. Lubrication ................................................................... 6-11

3.1 Lubrication chart for SheetMaster with GripMaster ....... 6-11
3.2 Lubricant ........................................................................ 6-12
X axis guide strip at the SheetMaster....................... 6-13
Pick-up columns of the carrier cups at the
SheetMaster ............................................................. 6-14
Stripper unit (optional) guide rod on the
SheetMaster ............................................................. 6-15
Safety device of the suction frame at the
SheetMaster ............................................................. 6-16
Guide rods of the sheet thickness gauge at the
SheetMaster ............................................................. 6-17
Central lubrication on the SheetMaster .................... 6-18
X axis feedgear at the SheetMaster ......................... 6-19
Z axis feedgear at the SheetMaster ......................... 6-19
Y axis feedgear at the SheetMaster (optional) ......... 6-19
Guide rails at the GripMaster.................................... 6-20
Stop pins on the movable GripMaster ...................... 6-20
Grippers on the GripMaster ...................................... 6-21
3.4 Lubrication chart for ToolMaster (40/70) ....................... 6-22
3.5 Lubricant ........................................................................ 6-23
Lifting device bearing................................................ 6-24
Indexing .................................................................... 6-25
Shifting unit (ToolMaster (70)) .................................. 6-26
Rotary table .............................................................. 6-27
Drive motor gearbox ................................................. 6-28

3.7 Lubrication chart for SortMaster Box ............................. 6-29
3.8 Lubricant ........................................................................ 6-30
Rolling elements of the four-point bearing................ 6-30
Inner toothing of slewing ring.................................... 6-32
3.10 Lubrication chart for SortMaster Pallet .......................... 6-33
3.11 Lubricant ........................................................................ 6-34
Cam .......................................................................... 6-34
Flange bearing unit................................................... 6-35
Roller chains and chain wheels ................................ 6-35
Flat gearbox.............................................................. 6-35
Screw joints .............................................................. 6-36
Weld joints ................................................................ 6-36
3.13 Lubrication chart for double unloading cart ................... 6-37
3.14 Lubricant ........................................................................ 6-38
Track rollers .............................................................. 6-38
Ball bearings ............................................................. 6-39
Flat gearbox.............................................................. 6-40
Screw joints .............................................................. 6-41
Weld joints ................................................................ 6-41
3.16 Lubrication chart for double cart with toothed
belt drive ........................................................................ 6-43
3.17 Lubricant ........................................................................ 6-44
Running surfaces...................................................... 6-44
Track rollers .............................................................. 6-44
Ball bearings ............................................................. 6-45
Flat gearbox.............................................................. 6-47
Screw joints .............................................................. 6-47
Weld joints ................................................................ 6-48
3.18 Lubrication chart for ShearMaster ................................. 6-49
3.19 Lubricant ........................................................................ 6-49
4. Pneumatic components .............................................. 6-57

4.1 Pneumatic components on the SheetMaster and
scissor table................................................................... 6-57
4.2 Overview ........................................................................ 6-57
Pressure regulator .................................................... 6-58
Vacuum hoses in the suction frame ......................... 6-60

Filters in the suction cup vacuum connections......... 6-61
Pneumatic bellows cylinder at the scissor table ....... 6-62
Pneumatic hoses at the scissor table....................... 6-62
5. Mechanical components ............................................. 6-63

5.1 Mechanical components at the SheetMaster and
GripMaster ..................................................................... 6-63
5.2 Overview ........................................................................ 6-63
Dowelling of SheetMaster, GripMaster and
support table with movable GripMaster.................... 6-64
Vacuum cups on the SheetMaster ........................... 6-65
X axis, Z axis, and Y axis (optional) cable tow
chains at the SheetMaster........................................ 6-68
5.4 Mechanical components on the ShearMaster ............... 6-69
Scrap container......................................................... 6-69
Conveyor belt............................................................ 6-70
6. Electrical components ................................................ 6-71

6.1 Maintenance of the electrical components at the
SheetMaster and scissor table ...................................... 6-71
Switch cabinet of the SheetMaster: TASC 100
control system battery .............................................. 6-71
Light barriers at the scissor table.............................. 6-72
Chapter 7 Test certificate - Noise level TruPunch 5000
1. Test certificate ............................................................... 7-2
2. Measurement result....................................................... 7-3
3. Reference workpiece..................................................... 7-4
4. Position of the measuring points................................. 7-5

Chapter 8 Aligning MSL safety light barrier
1. Additional equipment for the alignment

procedure ....................................................................... 8-2
2. Set-up example .............................................................. 8-3
3. Alignment procedure..................................................... 8-4

Chapter 1
Safety
1. For your safety............................................................... 1-3
2. Terminology ................................................................... 1-4
3. Operational safety ......................................................... 1-5

3.1 Intended use of the system.............................................. 1-5
3.2 Measures to be taken by the user/operator..................... 1-7
Danger signs and warnings ........................................ 1-7
Symbols ...................................................................... 1-7
Signaling words .......................................................... 1-8
Information on the source and type and how to
avoid the danger......................................................... 1-8
Instructing personnel .................................................. 1-9
Duty of care when handling the system ..................... 1-9
Eliminating malfunctions during operation................ 1-12
Using designated spare parts and operating
materials ................................................................... 1-12
Water protection ....................................................... 1-13
3.3 Measures taken by the manufacturer ............................ 1-14
Securing of the danger zone of the system.............. 1-14
B380EN01.DOC Contents 1-1

4. Laser safety.................................................................. 1-16
5. Danger due to magnetic fields ................................... 1-17
6. Overview of residual risks .......................................... 1-18
1-2 Contents B380EN01.DOC

1. For your safety
Your TruPunch 5000 is a combined punching and nibbling machine

which features the latest technology to insure reliable and safe
operation.
The declaration of EC conformity and the CE mark on the machine
confirm that the TruPunch 5000 complies with the standard safety
and health requirements of the EC Machinery Directive
of 98/37/EC.
Nameplate and CE marking Fig. 47753en
The nameplate and CE mark are on the C-frame in front of the

hydraulic tank of the TruPunch 5000.
As manufacturer of the system, we wish to acquaint you, the
owner, with the safety concept of the system, as well as provide
information about potential risks and measures by means of a
comprehensive chapter on safety.
Note
Please also observe any general safety regulations and accident
prevention regulations which are not included in this safety
information.
B380EN01.DOC 1BFor your safety 1-3

2. Terminology
Danger zone - TruPunch 5000 ... is the area within and around the machine where the safety or
health of persons is at risk. The danger zone comprises the area
which can be crossed by the transverse rail with a workpiece
(centered on the rail) that corresponds to the working range of the
machine, with an additional margin of 500 mm on all sides.
Danger zone - automation ... is the range of the SheetMaster which can be covered by the
vacuum carriage while carrying a workpiece with the suction cups,
with an additional margin of 500 mm on all sides.
The danger zone should be protected by appropriate safety
devices (e.g. fences, light barriers).
User/owner ... is the person on whose operating site the system is set up and
operated.
Operator/personnel ... are the persons responsible for the transportation, installation,
start-up, operation and maintenance (including cleaning) of the
machine and for the elimination of malfunctions and putting the
machine into service.
1-4 2BTerminology B380EN01.DOC

3. Operational safety
The system has been constructed with the latest technology and is
safe to operate.
The system can become a source of danger if it is used
inappropriately or other than intended:
• Dangers to the safety of the operator.
• Impairment of the system and other property of the user.
• Impairment of the working efficiency of the system.
3.1 Intended use of the system
TruPunch 5000 The TruPunch 5000 R is a CNC controlled sheet metal working
machine for punching, nibbling and forming flat workpieces made
of steel, copper, aluminum and corresponding alloys. Standard
values for the evenness of metallic material for hot rolled steel
sheets are DIN EN 10051 (Table 7, "Limited deviations" and DIN
EN 10029 (Table 5, class S). For cold rolled steel sheets, DIN EN
10131 applies (Tables 6 and 7, in each case "Limited tolerance
class").
Intended use also means:

• The system installation conditions specified by the
manufacturer for the machine and optional automation
components must be observed, and the maintenance work
must be carried out.
• The system must be installed and operated in accordance with
the national regulations which apply in the country where the
machine is operated. The user is responsible for their
compliance.
The following are not permitted:

• Unauthorized modifications and retrofitting of the system by the
user or operator.
• Any type of operation that poses a safety hazard.
B380EN01.DOC 3BOperational safety 1-5

Automation The SheetMaster is an automated device for loading and unloading
flat workpieces made of steel, copper, aluminum and
corresponding alloys. Scrap skeletons and residual strips are
removed from the basic machine by the GripMaster and deposited
on a scissor table.
Intended use also means:

• Only clean, dry and smooth workpiece surfaces which are not
heavily oiled ensure safe vacuum build-up on the suction cups.
Oxidized, heavily oiled or grained sheets may significantly
reduce the capacity of the suction cups.
• The owner must also ensure that measures have been taken
to prevent any potential risks which may arise due to a
workpiece which is held by the suction cups falling down or
due to a malfunction. These risks may arise during the loading
or unloading procedure, or when there is a failure of the
electrical or pneumatic energy supply.
• Furthermore it is forbidden to reach into the danger zone of the
SheetMaster during axis movement.
No liability is assumed for Any other form of use is regarded as other than intended. The
unauthorized use manufacturer is not liable for damage or injuries resulting from
such improper use; the owner has sole responsibility in this
respect.
1-6 3BOperational safety B380EN01.DOC

3.2 Measures to be taken by the
user/operator
Danger signs and warnings
Some of the actions which need to be performed when operating

the TruPunch 5000 are a potential source of danger. In this
operator's manual, instructions for conducting such procedures are
preceded by a warning. Furthermore, appropriate danger signs
have been affixed on the system.
Note
Please observe the warnings!
Follow the dos and don'ts given in the warnings. They are for your
own safety.
These warnings contain:

• A symbol.
• A key word.
• Information about the source and type of danger.
• Instructions on how to avoid the danger.
The form and content of the warnings are described in the

following sections.
Symbols
The warnings in the left column have symbols indicating the type of
danger.
A general danger symbol. The type of danger is further specified in

the corresponding hazard warning.
This symbol warns of a dangerous electrical voltage.

Furthermore danger signs with the following inscription have been
applied to the relevant components and cables in the switch
cabinet of the system which are connected in front of the main
switch: CAUTION! LIVE EVEN WHEN MAIN SWITCH IS
SWITCHED OFF. These components are live even when the main
switch is at OFF.

Signaling words
Warnings are indicated by one of the following signaling words:

• Danger
• Warning
• Caution
The key words have the following meanings:

Danger ... indicates a very serious hazard. Could lead to death and serious
injuries if not avoided.
Warning ... refers to a dangerous situation. Could lead to serious injury or

significant damage to property if not avoided.
Caution ... indicates a potentially dangerous situation. If these are not

prevented, they could result in minor injuries or damage to
property.
Information on the source and type and how

to avoid the danger
The warnings contain information about the source and type of the
danger and instructions on how to behave in order to avoid such
dangers.
Example:
Unfiltered oil can destroy the hydraulic system!

Warranty claims are rendered void.
¾ When filling, use a filler with a fineness of at least 6 μm, or a
Caution return filter.
¾ When filling and during operation:
Make sure the oil and air filter element and the blue locking
cap are left on the return filter.

Instructing personnel
Only authorized, trained and instructed personnel may be

entrusted with the operation, maintenance and service of the
system.
Work on hydraulic, pneumatic and electrical equipment may only
be performed by specially trained technicians.
Furthermore, the following measures must be taken before
personnel can begin to work on the system:
• Instruct personnel about potential dangers.
• The user must, if necessary, ensure that the personnel wear
protective clothing and gloves.
• The areas of competence for operation, maintenance and
repairs must be clearly defined in order to avoid any ambiguity
concerning safety.
• Read the technical documentation of the system. We
recommend that the user has the personnel confirm in writing
that they have read and understood the technical
documentation.
Duty of care when handling the system
Safety devices and danger • The system may only be operated with the appropriate safety
zones of the system devices used to secure the danger zone.
• Safety devices must not be dismantled or switched off. If,
however, this is required for maintenance or repair work,
reinstall the safety devices immediately after finishing the work
and restore them to service.
• The light barrier must be checked for operability once per shift
(ideally before beginning production).
• The light barrier must also be tested for operability:
– If the arrangement of light transmitter and light receiver has
been changed.
– After all maintenance or service work on the light barrier.
Note
The operator must always make sure nobody is within the danger
zone before the system is started up. If he enters the danger zone
himself, he must take off the "feed hold ON/OFF" key on the
control panel and keep it safe.

Ensure that the system is in • The user or the persons authorized by the user may operate
perfect working order the machine only when it is in perfect working order.
• The user must set up the system in accordance with the
installation plan and installation conditions.
• The user must ensure the work station at the machine is clean
and tidy by issuing appropriate instructions and conducting
inspections.
• The user must ensure that the working ranges are supplied
with sufficient fresh air.
• Modifications (including those regarding operating
performance) in the system that impair safety, must be
immediately reported to the user by the operator. For this, the
system should be checked for visible defects and damage at
least once per shift.
• The operator is responsible for inserting the workpiece and for
clamping the workpiece safely in the clamps when
repositioning it. There is a positional accuracy of ±0.1 mm for
repositioning, which depends on the evenness of the sheet
and the repositioning position.
Machining oversized sheets When equipped with a safeguarding device, the machine can be
used to process sheet formats of sizes 2500 x 1260 mm
(TruPunch 5000, medium format) and 3048 x 1570 mm
(TruPunch 5000, large format).
Side tables are required to support the sheet when machining
oversized sheets. In this case, special table extensions have to be
installed at the machine. The user is responsible for the
appropriate selection and installation of the side tables and for
securing the enlarged danger zone.
Observing the shutdown The prescribed shutdown procedures must be adhered to for all
procedure work regarding transport, installation, start-up, operation,
maintenance and repairs:
• The system must always be switched off using the main
switch, the main switch must be locked and the key must be
removed during setting, maintenance or repairs. Any
exceptions to this rule requiring that the system remain
switched on during corresponding work are specified in the
Operator's manual.
• The accumulator must be depressurized prior to any work on
the hydraulic system, punching head, die adapter or clamps to
avoid any residual pressure. The following sign indicates
dangers concerning the hydraulic pressure:

Fig. 19481en
• The sign should be attached on the hydraulic unit as well as on

the inner side of the cover hood of the punching head.
• For work on the pneumatic system:
– Shut off and lock the compressed air supply.
– Wait at least five seconds for the pressure to drop after
cutting off the compressed air supply.
– Check whether the operating pressure has fallen to 0 bar.
To do this, read off the current operating pressure at the
corresponding pressure gauge.

Eliminating malfunctions during operation
1. Press FEED HOLD.

2. Eliminate the malfunction on the control panel.
3. If the malfunction cannot be eliminated using the operating
panel: press E-STOP.
4. Eliminate the malfunction by intervening briefly in the system.
5. If the malfunction has to be eliminated through maintenance or
repairs:
– Switch off the main switch.
– Lock the main switch.
– Pull out the key.
6. Initiate maintenance and service work.
Using designated spare parts and operating

materials
Original parts and Original parts and accessories have been designed specially for
accessories the system. Spare parts for original parts and accessories other
than those supplied by the manufacturer of the system have not
been checked and approved by the manufacturer. The installation
and/or use of such products may therefore possibly change the
original design characteristics of the system and impair safety.
Note
The manufacturer accepts no liability for damage caused by the
use of non-original parts and accessories or by the incorrect
installation or replacement of original parts and accessories.

Operating materials The usage instructions must be observed when using the specified
operating materials (in particular lubricants and cleaning agents). If
a safety specifications sheet (European Directive 91/155/EEC,
93/112/EC) is required by the manufacturer for an operating
material, the instructions it contains must be complied with, such
as e.g.:
• Chemical properties.
• Physical and safety-related specifications.
• Transport
• Regulations
• Safety measures, storage, and handling.
• Measures to be taken in the event of accidents and fires.
• Toxicological information.
• Ecological information.
This also applies in particular to the appropriate disposal of

operating materials. The prescribed disposal method and the
waste code have been specified in the safety specifications sheet.
Safety data sheets can be obtained from the manufacturers of the
respective operating materials.
Water protection
In the Federal Republic of Germany, the principle of precaution

applies to all machines that use materials which could pollute
water. This principle states that no water contamination may result
from the use of such substances. This is the central statement of
§ 19 of the German water resources law (Wasserhaushaltsgesetz -
WHG). The plant decrees (VawS [Decree on Facilities for Handling
Water-polluting Substances]) and administrative regulations
(VVAwS [Administrative Regulation for Facilities for Water-polluting
Substances]) of the Federal States specify how to adhere to this
principle of precaution.
Water-pollutant substances Hydraulic oil and lubricants

Water hazard class WHC 2
Hydraulic oil operating pressure 260 bar
Volume of water-pollutant substances ≤1000 l
Hazard level of the entire system A
Water protection specifications Table 1-1
Cooling water Cooling water may only be discharged together with waste water in
agreement with the local waste disposal authority.

3.3 Measures taken by the manufacturer
Securing of the danger zone of the system
The danger zone of the system is secured through corresponding

safety devices. The system may be operated only with these safety
devices.
A dual-beam light barrier used to secure the danger zone belongs
to the standard equipment of the system. Alternatively, the user
can secure the danger zone with his or her own equipment. In this
case, the user is also responsible for the observance of the safety
regulations.
The operator must take additional measures to eliminate dangers
that may arise, for instance, when machining workpieces with
unusual contours, larger sheets, sheets clamped off-center (e.g.
when repositioning) or when using side tables.
Automation When using a ToolMaster (40/70), a second light barrier secures

the operator during set-up work (option for set-up work in
productive time).
Note
The operator must always make sure nobody is within the danger
zone before the system is started up. If he enters the danger zone
himself, he must take off the "feed hold ON/OFF" key on the
control panel and keep it safe.
The danger zone of the system can be secured by means of light

barriers in all submodes of the control system.
If the light beam is interrupted during operation, FEED HOLD is
triggered. All system movements are stopped automatically.
¾ In order to switch the system back on after interrupting the light

barrier: acknowledge the light barrier and press START on the
control panel of the system.

Service switch for service A service switch has been provided for certain service and setting
and setting work work that is carried by TRUMPF service technician or trained
personnel.
The service switch is in the switch cabinet. It can be turned to three
positions using the key. The key can be removed in settings 1 and
2. These positions are reserved exclusively for service work by the
TRUMPF service technicians or trained personnel.
Switch setting 0 • Automatic mode.

• The safety light barrier is active.
• Correct switch setting for use by the customer.
Switch setting 1 • Automatic mode not possible.
• All movements which could be a source of danger are de-energized.
• In this position, the TRUMPF service technician can release the holding brake for the ram
using the button on the punching head.
Switch setting 2 • Automatic mode is possible only at 2 % of the maximum speed.
• The safety light barrier is bridged.
• The travel speed for all axes is reduced to 2 % of maximum speed.
• A mechanical limit for the X and Y axes (e.g. chip block or clamping element, stop parts for
Y axis in the accessories) is fitted by the TRUMPF service technician for performing
measurements on the punching head and for measuring the concentricity, parallelism and
backlash.
Table 1-2
EMERGENCY STOP impact EMERGENCY STOP triggers the following machine functions:
button • The power supply to the system is interrupted (24 V control
voltage is retained).
• All axes motions stop.

4. Laser safety
Stripper detection The machine is equipped with a scanner, near the punching head,
for detecting the stripper.
This scanner operates using a class 2 laser in accordance with EN
60825-1.
Wavelength 655 nm
Max. output < 4.0 mW
Pulse duration 5 μs
Laser class Class 2
Technical specifications of the laser Table 1-3
Signs 1 and 2: laser warning symbol and information Fig. 3616+35725en

sign
1-16 4BLaser safety B380EN01.DOC

5. Danger due to magnetic fields
The SheetMaster is equipped with a device for the separation of

ferromagnetic sheets using expanding magnets. These permanent
magnets generate a strong magnetic field and consequently a high
ferromagnetic attractive force. The magnetic field and the attractive
force are constant, regardless of whether the machine is switched
on or off (even if the main switch is switched off).
Magnetic flux density The magnetic flux density is at its highest with about 180 mT
(millitesla) at the front surfaces of the expanding magnets. The
magnetic flux density falls proportionally to the square of the
distance. The value is approximately 0.3 mT at a distance of
20 cm.
Strong magnetic fields can cause risk of fatal injury to

persons with pacemakers!
¾ Persons with pacemakers must keep a minimum distance of
Danger 20 cm to the permanent magnets (expanding magnets).
¾ Notify personnel, visitors, or visiting personnel of the dangers
for persons with a pacemaker.
Pacemaker warning sign
Fig. 19425
The loading station has 2 expanding magnets. Each of the 2

expanding magnets has a "Pacemaker" warning sign, as shown
above.
Risk of injury due to high force of attraction!

¾ Do not bring any magnetic tools or workpieces near the
permanent magnets.
Warning ¾ Do not bring any clocks or magnetic storage mediums (disks,
credit cards) near the permanent magnets.
Risk of hands being crushed between sheet and expanding

magnets in the course of manual loading.
Expanding magnets have a high attractive force, particularly
Warning if the distance is < 50 mm.
¾ Do not put your hands between sheet and expanding
magnets in the course of manual loading.
B380EN01.DOC 5BDanger due to magnetic fields 1-17

6. Overview of residual risks
The machine can be a source of residual risks in spite of the safety

equipment, the design and the construction type.
The following overview of residual risks is a summary of the main
potential threats to life and limb posed by the machine.
Any additional precautions that can be taken by the machine owner
to reduce residual risks are specified in the overview of residual
risks.
Residual risks Dangerous point Type of danger Measures to be taken

by the operator
Mechanical elements
Crushing • Hydraulic punching head. Risk of injury -
• Clamps
• Chip flap.
• Tool clamp.
• Coordinate guide with punching head.
• Removal of small parts.
• Chip conveyor (optional).
• Conveyor belt (optional).
• Repositioning device (optional).
• SheetMaster:
– Suction frame/machine table.
– Suction frame/loading and unloading.
– Falling sheet.
– Scrap skeleton on the scissor table.
– Closing grippers.
– Gripper bar/
GripMaster pedestal.
– Scissor table.
• ToolMaster (40/70):
– Lowering the grippers onto the
rotary plate/ transverse rail.
– Closing movement of the grippers.
– Coordinate guide operation in tool
change position.
– Rotational movement of the swivel
arm.
– Operation of the shifting unit
(ToolMaster (70)).
• SortMaster Box:
– Turnstile and container in the scrap
skeleton pedestal and chip conveyor
areas.
• ShearMaster:
– Blade slide down.
– Blade slide up.
– Presser foot down.
– Slide in the working stroke.
– Conveyor belt in the upstroke.
– Loading scrap skeleton.
– Scrap skeleton feed.
1-18 6BOverview of residual risks B380EN01.DOC

by the operator
Cutting and cutting to size • Hydraulic punching head. Risk of injury -
• Moving workpiece: small parts
chute/punching head.
• SheetMaster: Do not reach into the
– Workpiece danger zone
– Scrap skeleton.
• ShearMaster: -
– Blades down to the kerf setting.
– Cutting movement of the blades
down.
– Sharp-edged scrap skeleton or parts Wear work gloves
of it in the scrap bucket.
– Cutting along the blade edges when
working on the blade.
Shearing • Scissor table. Risk of injury -
– Using the tools in the tool adapter in
the rotary plate/transverse rail.
• ShearMaster: Wear work gloves
– Blades down to the kerf setting.
– Cutting movement of the blades
down.
Getting caught or due to • ToolMaster (40/70): Risk of injury -
winding – Rotational movement of the rotary
plate.
– Driving pinion for the toothed wheel
rotary plate.
• ShearMaster:
– Conveyor belt in the working stroke.
Joint • Transverse rail with workpiece. Risk of injury -

• Base plate.
• Moving sheet. If the sheet >the
standard working
range, secure the
enlarged working
range
• SheetMaster: Do not reach into the
– Suction frame X movement. danger zone
– Suction frame Y movement.
– Gripper bar X/Y movement.
• ToolMaster (40/70): -
• Rotational movement of the swivel arm.
• ShearMaster:
B380EN01.DOC 6BOverview of residual risks 1-19

by the operator
Due to fluids and gases • Hydraulic lines. Risk of injury -
being expelled under high • Pressure accumulator.
pressure • SheetMaster:
– Pneumatic hoses.
• ShearMaster:
– Hydraulic hoses.
Ejection of parts • Workpiece Risk of injury -

– Tool in the gripper.
– Tool on the rotary plate.
• ShearMaster:
– Scrap skeleton pieces.
Falling of loads • ShearMaster: Risk of injury -

– Scrap skeleton.
Unsuitable means of • ShearMaster Risk of injury Use suitable, approved

transportation means of
transportation
(shackles, strips, etc.)
Through elastic elements • ShearMaster: Risk of injury -
(springs) breaking – Presser foot springs, turnbuckle
(cable belts).
Instability • SheetMaster unstable. Risk of injury -

• GripMaster not independently stable.
• The workpiece falling down from its own
weight when the low pressure drops.
Electrical system
Electric contact • Directly with normally live parts. Risk of fatal injury -
• Indirect contact with parts which are live
when faulty.
Noise
Damage to hearing • Punching/nibbling. Health risk Use whispertools
• Skeleton removal. Wear hearing
protection
Hazards due to substances
Contact with or inhaling of • Tool spray lubrication. Health risk • Use lubricants
toxic fluids, gases, mist, sparingly.
fumes or dust • Ventilate the work
station well.

by the operator
Malfunction or incorrect function
Malfunction of energy • Drives Risk of injury -
supply • Control voltage.
SheetMaster: Malfunction in • Pneumatics Risk of injury -
the vacuum supply
Magnetic fields
Strong magnetic field of the SheetMaster (optional) expanding magnets Mortal danger to Minimum distance of
permanent magnet, persons with 20 cm to be
regardless of whether the pacemakers maintained by people
machine is switched on or with pacemakers
off
Table 1-4
B380EN01.DOC 6BOverview of residual risks 1-21

Chapter 2
TruPunch 5000
Installation Conditions
Drawing number: 9120-5-20.EN
Material number: 967914
B380EN02.DOC TruPunch 5000 installation conditions – Version 11 2-1

Contents
Responsibilities.......................................................................... 2-3
1. Planning aid ................................................................... 2-4
2. Installation site............................................................... 2-6

2.1 Space requirements......................................................... 2-6
2.2 Floor requirements........................................................... 2-6
2.3 Load indications............................................................... 2-8
2.4 Ambient conditions ........................................................ 2-11
2.5 Air purity......................................................................... 2-11
3. Electrical supply .......................................................... 2-12

3.1 Power supply ................................................................. 2-12
Isolating transformer................................................. 2-13
3.2 Connected loads/fuse protection ................................... 2-15
3.3 Remote diagnostics ....................................................... 2-15
3.4 Network connection ....................................................... 2-16
4. Compressed air supply ............................................... 2-17
5. Operating materials ..................................................... 2-20

5.1 Operating materials for the hydraulic system ................ 2-20
5.2 Cooling water for the cooling unit .................................. 2-21
5.3 Materials ........................................................................ 2-21
5.4 Pallets for SheetMaster (optional) ................................. 2-23
5.5 Older tool cartridges ...................................................... 2-23
5.6 New MultiTools and tapping tools.................................. 2-25
6. Transport ...................................................................... 2-26

6.1 Measures to be taken by the customer ......................... 2-27
Machine delivery....................................................... 2-27
Unloading the machine from the truck...................... 2-28
Transporting the machine to the installation site ...... 2-31
Installing the machine............................................... 2-32
2-2 TruPunch 5000 installation conditions – Version 11 B380EN02.DOC

Responsibilities
Customer All the conditions described in this chapter must be fulfilled before
the machine is delivered.
If this is not the case, the TRUMPF Service personnel will not be
able to put the system into service.
Note
The main switch on the machine may only be switched on by
TRUMPF service personnel.
TRUMPF Service The machine is put into service by TRUMPF Service technicians.
This includes:
• Installing, aligning, leveling and securing the machine.
• Filling oil.
• Connecting the machine to the supplies (with the exception of
the electrical power supply).
• Performing a functional test.
• Instructing personnel.
Note
• In case of air freight, the hydraulic oil is separately delivered. In
this case, it is necessary to fill the oil. An oil pump is included
in the scope of delivery. Except the exception mentioned
below, the oil is already in the hydraulic oil tank.
• Due to the dangerous goods regulations, the machine must be
delivered without filling in some countries. This exceptional
regulation is referred to at the end of the contract.
B380EN02.DOC 1BPlanning aid – Version 11 2-3

1. Planning aid
30 31
The planning aid is intended to provide you with an overview of the
measures to be taken and preparations to be made by the
customer.
Detailed information can be found in the respective sections of the
installation conditions.
Time before delivery of the machine Planning criterion Measures

15 weeks Personnel and training ¾ Appoint a member of staff to be
responsible for preparations for the
delivery of the machine.
¾ Appoint operators, maintenance
technicians and programmers.
¾ Arrange training schedules for
specialist personnel.
14 weeks, Conditions at the installation site ¾ Determine the installation site of

but no later than calendar week ... the machine, taking into account
the space requirements according
20 to the installation plan.
¾ Check the floor requirements:
– Floor quality
– Evenness
– Oil-resistant floor without
expansion joints
¾ Take the weight and dimensions of
the machine into account.
¾ Check the requirements for
ambient conditions:
– Room temperature
– Exposure to sunlight
¾ Check the transport route:
– Gate openings
– Header heights
– Cable rack heights
– Shunting areas around corners
– etc.
12 weeks, Electrical supply ¾ Install the electrical connections at

but no later than calendar week ... the installation site. Lay the
conductor cross-section and fuse
protection according to the legal
requirements.
¾ Have the work required for remote
diagnostics carried out.
12 weeks, Compressed air supply ¾ Install the compressed air supply

but no later than calendar week ... at the installation site:
– Connection
– Purity
– Compressed air requirements
2-4 1BPlanning aid – Version 11 B380EN02.DOC

Time before delivery of the machine Planning criterion Measures
4 weeks, Operating materials ¾ Keep a stock of operating
but no later than calendar week ... materials:
– Hydraulic oil (follow the notes in
the document)
– Demineralized water
4 weeks, Transport ¾ Ensure the required transport aids

but no later than calendar week ... are available.
4 weeks, Test workpiece ¾ Prepare two sheets for the

but no later than calendar week ... machine test:
– 1000 x 1000 mm
– USt 12.03 (DIN EN 10131)
– s = 2.5 mm
Planning aid Table 2–1
B380EN02.DOC 1BPlanning aid – Version 11 2-5

2. Installation site
2.1 Space requirements
The arrangement of the individual components and the space

20 requirements for standard installation have been documented in
the installation plan that applies in each case. The required space
for opening the doors of the switch cabinet is illustrated there.
If the installation deviates from the standard installation plan, a
special installation plan is required.
The installation plan delivered with the system is always valid.
2.2 Floor requirements
Evenness • As far as possible, a leveled floor is desired as the foundation

of the system.
• The variation in height across the area of the machine and the
SheetMaster must not exceed 12 mm.
• Minor unevenness can be compensated for using adjustable
legs or wedge mounts.
Installation surface • The entire installation surface of the machine and the
SheetMaster must consist of a continuous base plate with a
smooth surface in the area of the load-bearing points. This
applies in particular to the area around the wedge mounts.
• The floor must be oil-proof (Water Resources Act).
Note
External influences due to changing loads in the immediate vicinity
of the system can affect the quality of the workpieces. These
include, for example:
• Fork lifts, industrial trucks, etc.
• The installation or removal of other machines in the immediate
vicinity of the system.
• The operation of machines that excite vibrations, such as
punch presses etc.
• The maximum permissible acceleration at the support points of
the laser (or basic machine) is 0.1 x the acceleration due to
gravity.
Exact inspections must be conducted in individual cases.
2-6 2BInstallation site – Version 11 B380EN02.DOC

Elastically cushioned base TruPunch 5000 TruPunch 5000
plate (medium format) (large format)
Effective load (kN/m²) 20 30
Minimum thickness (mm) 200 250
Table 2-2
• Concrete quality (equivalent to tensile strength C 25/30):

– Cylinder compressive strength fck ≥25 N/mm².
– Cube strength fck, cube ≥30 N/mm².
• Concrete steel reinforcement with:
– characteristic rated value fyd ≥435 N/mm².
– An elasticity module of Es ≥200.000 N/mm².
– an upper crosswise reinforcement of min. 3.7 cm²/m each.
– a lower crosswise reinforcement of min. 3.7 cm²/m each.
• Elastic cushioning of the base plate on a foundation with a
minimum ballast number C ≥5000 kN/m³ (loess loam).
• No joint of any kind may be located in the area of the machine
or within at least 1.0 m of it.
Ceiling plate/ TruPunch 5000 TruPunch 5000

free span base plate (medium format) (large format)
Effective load (kN/m²) 20 30
Minimum thickness (mm) 200 250
Table 2-3
• Plates as multiple span girders.
Note
Calculations must be made by a structural analyst if these
requirements are not met or bearing technology is used!
B380EN02.DOC 2BInstallation site – Version 11 2-7

2.3 Load indications
Note
In punching mode, the wedge mount installation places an
additional dynamic load on the support points P3 and P4.
In the case of air-cushioned installation (optional), the dynamic
load on the support points is reduced by about 80 %.
Structural stress analysis • Subject the load capacity of the floor to a structural stress
analysis prior to the installation.
• Take into account the weights of the relevant components and
the load on the support points.
Machine without automation
Component Weight Load on the support points Distribution of weight

kg N
TruPunch 5000 13700 • P1: max. 29860. Weight support by means of
(medium format) • P2: max. 29860. 4 wedge mounts or 4 air cushions
• P3: max. 56130. elements (optional)
• P4: max. 56130.
TruPunch 5000 17300 • P1: max. 38660.
(large format) • P2: max. 38660.
• P3: max. 66900.
• P4: max. 66900.
Switch cabinet 700 - The edges support the main load
Control panel 100 -
Cooling unit 65 - -
Weights and load Table 2-4

Automation
Component Weight Distribution of weight

KG
SheetMaster (1305) 3200 The weight is supported by
12 surfaces (100 x 100 mm each).
SheetMaster (1605) 3400
SheetMaster (1605, plus) 3700 Weight supported by:
• Pedestal close to machine:
4 surfaces (each 100 x 100 mm)
• Pedestal not close to machine:
6 surfaces (each 100 x 100 mm).
SheetMaster (1305/1605) Max. static load - pedestal A The load is supported by 6 surfaces
(close to the machine): 2000 per pedestal.
Max. static load – pedestal -
stand B
(not close to machine): 2000
Additional dynamic load: approx.
650
Control cabinet 413 The edges support the main load.
GripMaster 250 Weight support using four wedge
mounts.
GripMaster (Plus) 900
Support table with GripMaster (Plus) 700 -
ShearMaster 3200 Weight support using four wedge
mounts.
Conveyor table for ShearMaster 700-800 Weight support using four adjustable
legs.
Scrap conveyor for ShearMaster 550 Weight support using four rollers.
Scrap container for ShearMaster 150/400
Scissor table 1305, including skeleton approx. 6000 The edges support the main load.
stack
Scissor table 1605, including skeleton approx. 6000
stack
Scissor table 1605, incl. skeleton stack approx. 6500
with GripMaster (Plus)
Weights and load Table 2-5

Weight support
Example: TruPunch 5000 (medium format) Fig. 36463
642
440
440
642
3060
P1 P2
642
390
390
642
P4
P3
475
Example: TruPunch 5000 with automation (medium format) Fig. 36464

2.4 Ambient conditions
Ambient temperature for the Acceptable ambient temperature for the operation of the machines:
machine • +10 to +40 °C
The temperature at the installation position must not be allowed to

drop below +4 °C when the machine is off.
¾ One-sided exposure to direct sunlight and unidirectional drafts

(heat distortion) should be avoided (e.g. by Venetian blinds if
the control unit is installed near a window).
Ambient conditions for the Acceptable humidity for the control system during transport or
control system when the machines are switched off:
• 20 to 75 % relative air humidity.
The control system is cooled in the closed switch cabinet only. It is

cooled actively by a cooling compressor, which is automatically
switched on at an inside temperature of ≥35 °C.
The switch-on temperature has been set to this value at the
factory. The nominal temperature of the switch cabinet must not be
set too low, since otherwise the temperature would fall below the
dew point and condensation would form.
¾ Make sure the air inlet and outlet openings are free. The
distance to the wall or the nearest device must be at least
200 mm.
Control panel cooling The control panel is cooled by means of two fans. Filter mats
prevent dirt particles from entering the control panel.
2.5 Air purity
TruPunch 5000 Air impurities from nearby machines or systems (e.g. welding
machines, cleaning stations etc.) can cause malfunctions. Secure
intake of the sheet by the SheetMaster cannot be ensured if there
is a large amount of dust on the sheet surfaces or if they are very
dirty.
¾ Protect the SheetMaster from excess dirt by taking appropriate

measures (partitions, suction systems etc.).

3. Electrical supply
The system is designed at the factory for one of the following

nominal voltages:
Nominal voltage Frequency

400 V ±10 % 50 Hz ±1 %
460 V +10 %/– 5 % 60 Hz ±1 %
Table 2–6
¾ Install an isolating transformer if the nominal voltage deviates

permanently from 400 V ±10 % or 460 V +10 %/– 5 %.
¾ Set up the power supply at the control cabinet of the machine
according to the installation plan.
Electrical power supply Connecting line

Cables Cross section Ground wire
Regulation: Regulation: Version according to According to VDE 0100
Version according to Four-pole copper cable (L1, VDE 0100 part 540
DIN EN 60204-1/4.3.1 L2, L3, PE) Section 430 (IEC 60364-5-54)
Single strand or multi strand
with wire end ferrules
Connection must be
protected against direct
contact
Clockwise phase rotation
Table 2–7
3.1 Power supply
Residual current protective Only type B is permitted if a residual current circuit breaker is used
device on the line side for protection against direct or indirect contact (see
EN 50178 Section 5.2.11.2; VDE 0160, April 1998). TRUMPF
recommends devices from the RCMA series of Messrs. Dipl. Ing.
W. Bender GmbH & Co. KG or devices from the DFS 7B series of
Messrs. Doepke Schaltgeräte GmbH & Co. KG.
If, when using a fault current circuit breaker, the machine's leakage
current is greater than the set fault current, the machine and the
network must be separated by an isolating transformer (see EN
50178 Pt. 5.2.11.1; VDE 0160, April 1998 edition).
¾ Install an isolating transformer if the leakage current of the
machine is higher than the set fault current when using a
residual current circuit breaker.
Line structures ¾ Install an isolating transformer for IT and TT network structures

and asymmetrical networks (one phase grounded).
2-12 3BElectrical supply – Version 11 B380EN02.DOC

Isolating transformer
An isolating transformer must be installed in the following cases:

• If the nominal voltage deviates from 400 V ±10 % or 460 V
+10 %/– 5 %.
• For IT and TT network structures and asymmetrical networks
(one phase grounded).
• If the leakage current of the machine is greater than the set
fault current when using a fault current circuit breaker.
The following information must be observed if the machine is

equipped with an isolating transformer:
• The short-circuit current must be ≤2.4%.
• The manufacturer's documentation is applicable for the
isolating transformer.
• The customer must determine the location of the isolating
transformer.
• The isolating transformer must be installed in such a way that
access via the door hung on the front side (door with
nameplate) remains free. A safety distance of 800 mm must be
observed. The minimum distance on the sides and at the rear
is 100 mm (see Fig. 22793, p. 14).
• The customer must provide and lay the connection cable.
• The connection cable to the isolating transformer and from the
isolating transformer to the control cabinet of the machine can
be laid into the isolating transformer using PG48 screw joints:
– From the sides.
– From the rear at the top.
– From the rear at the bottom.
Machine without an active die Machine with an active die

Series transformer MD30000 MD63000
Roller and Fischer
Dimensions: 800 x 600 x 1200 1050 x 750 x 1400
Length x Width x Height in mm
Mat. no. 142587 142588
Isolating transformer data Table 2-8
B380EN02.DOC 3BElectrical supply – Version 11 2-13

800 mm
600 mm
1
800 mm
2
1 Isolating transformer 2 Safety distance

Space requirements of the MD30000 isolating Fig. 22793
transformer

3.2 Connected loads/fuse protection
Machine incl. SheetMaster

and ToolMaster
Without active die With active die

Connected load kVA 29 38
Max. fuse protection A 50 63
(at 400 V or 460 V)
Max. permitted interruption of the Refer to EN 60204, Part 1, Section 4.3.2, Alternating Current Supply.
nominal voltage
Electrical power input kW 11.2 12.2
Table 2-9
Note
If a TruPunch 5000 without active die is replaced with a
TruPunch 5000 with active die, the electrical connection must be
rechecked as regards the connected load and the fuse protection.
3.3 Remote diagnostics
TRUMPF provides the following interfaces in the control cabinet of

the machine:
• Analog modem.
• RJ11 plug.
• Telephone adapter for the telephone socket used in the
particular country (e.g. TAE6-N coupling in Germany)
¾ The customer should take the following measures:

– Installation of a telephone socket for an analog modem on
the machine's control cabinet by the respective telephone
company.
– A digital connection must be converted to an analog
connection by a converter.
– It must be possible to access the modem with a direct
dialing number. Otherwise, a separate exchange line is
required.
B380EN02.DOC 3BElectrical supply – Version 11 2-15

3.4 Network connection
TRUMPF provides the following interfaces for the network

(programming system) in the control cabinet of the machine:
• BNC plugs for customers with RG58 network cabling.
• RJ45 plugs for customers with shielded twisted pair network
cabling.
Personal hub (network A personal hub (network distributor) is required if several machines
distributor) are to be integrated in the network. It can be found in the control
cabinet of the machine and must be supplied with AC current by
the customer, since the distributor function must even be ensured
when the machine is switched off.
Note
When using a personal hub (network distributor), the tolerances of
the nominal voltage and the frequency apply (see section 3,
page 12).
Power supply ¾ Provide a power supply:

– Outside the USA and Canada: 230 V with grounded socket
or in accordance with the national standard. The grounded
coupling is delivered with the machine.
– In the USA and Canada: 115 V with plug socket in
accordance with the US standard.

4. Compressed air supply
The compressed air supply can be flexible or of fixed piping.
TruPunch 5000 Line pressure 7 - 14 bar

Min. nominal diameter of the supply DN 9 (inside diameter 9 mm)
line
Compressed air consumption ∅ 22.6 Nm3/h
Max. compressed air consumption 48.5 Nm3/h
Max. hose length 10 m
Table 2–10
SheetMaster Line pressure 7 - 14 bar

Min. nominal diameter of the supply DN 25
line (separate supply line for (inside diameter 25 mm; 1 inch)
SheetMaster)
Compressed air consumption ∅ 21.2 Nm3/h
Max. compressed air consumption 90.5 Nm3/h
Max. hose length 20 m
Table 2–11
The user must provide a maintenance unit so that the compressed

air at the tapping point has the following properties:
Property Requirement Quality class Measure (recommended)

ISO 8573-1 (2001
edition)
Condensate-free Cooled down to +7 °C (pressure dew point) 4 Cold dryer
Dust-free Maximum particle size: 15 μm 7 Air filter in front of the
3 system
Max. particle density: 8 mg/Nm
Oil-free Max. oil content: 5 mg Nm3 4 Oil-free compacting screw-
type compressor
Compressed air properties Table 2–12
Compressor ¾ If the compressed air supply for the machine is insufficient,

provide an appropriate compressor. Due to the risk of
condensation build-up, make sure the maximum distance
between the compressor and the machine does not exceed
50 m.
B380EN02.DOC 4BCompressed air supply – Version 11 2-17

Supply lines Components
1 Main line for machine with 5 Machine
SheetMaster 6 SheetMaster
2 To the machine 7 GripMaster
3 To the SheetMaster A Connection points for the
4 To the GripMaster customer
Pneumatic connection of a TruPunch 5000 Fig. 55141
Since the vacuum at the SheetMaster is generated by compressed

air, the pneumatic system must be effectively protected against
pressure drops under 7 bar. This is applicable even when drops in
pressure are brief.
Tip
A compressed air reservoir with a condenser drain with an
upstream non-return valve improves the compressed air supply
considerably.
In addition, we recommend that the non-return valve is protected
by a filter.
The installation of a 3/2 directional manually operated ball cock is
recommended in order to separate the compressed air reservoir
from the compressed air network for maintenance work on the
SheetMaster.
Compressed air Vmin > 100 l E.g. from Mannesmann-

reservoir with condenser Rexroth
drain
Non-return valve 1" E.g. G 1", Herion
(order no. 4055501)
Filter Fineness of 40 μm E.g. G 1", Herion
(order no. 4170260)
Pneumatic connection - TRUMPF material
(optional) number: 09363211
Table 2–13
2-18 4BCompressed air supply – Version 11 B380EN02.DOC

1 Line from the network 5 Compressed air reservoir
2 Filter 6 Line to SheetMaster
3 Non-return valve
4 3/2 directional manually
operated ball cock
Pneumatic system of the SheetMaster secured Fig. 26327
against pressure drops
¾ If the compressed air network is at full capacity or temporarily

overloaded, install the compressed air reservoir in the supply
line in front of the maintenance unit of the SheetMaster.
¾ Secure the compressed air reservoir against the compressed
air network with a non-return valve.
¾ Install the 3/2 directional manually operated ball cock.
B380EN02.DOC 4BCompressed air supply – Version 11 2-19

5. Operating materials
5.1 Operating materials for the hydraulic

system
Note
• Hydraulic oil is delivered separately when air freight is used. In
this case, it is necessary to fill the oil. An oil pump is included
in the scope of delivery. Except the exception mentioned
below, the oil is already in the hydraulic oil tank.
– Due to the dangerous goods regulations, the machine
must be supplied empty in some countries. This
exceptional regulation is referred to at the end of the
contract.
• The hydraulic tank of the hydraulic system of the machine
should be filled only with filtered oil. The filters used for this
purpose must have a filter pore size of 6 μm.
Hydraulic oil Specification Filling volume Filling point

(according to DIN 51524) l
• SHELL Tellus Oil DO 46. HLPD/ISO VG 46 Max. 230 Hydraulic oil tank of the
machine
• MOBIL DTE 25.
• Castrol Hyspin DSP 46. 160 ShearMaster hydraulic oil
tank (optional)
• Fuchs Renolin MR 15.
Operating materials for the hydraulic system Table 2-14
2-20 5BOperating materials – Version 11 B380EN02.DOC

5.2 Cooling water for the cooling unit
Cooling water is needed for cooling the driver motors for the
coordinate guidance and to cool the machine body.
Note
The scope of delivery of the machine includes "Easy-Kit Drives" for
preparation of demineralized water. Easy-Kit Drives contain
substances for corrosion protection, protection against
bacteria/algae and for cleaning.
Machine without an active die Machine with an active die

Cooling water, Quantity l 100 130
demineralized (purge 50, fill 50) (purge 65, fill 65)
Table 2-15
Damage is caused to the machine if tap water is used.

¾ Use demineralized water.
Caution
5.3 Materials
Evenness of metallic The following recommended values apply for the evenness of
materials metallic materials:
• Hot rolled steel sheets:
– DIN EN 10051 (Table 7, "Reduced deviations")
– DIN EN 10029 (Table 5, class S)
• Cold rolled steel sheets:
– DIN EN 10131 (Tables 6 and 7, each with a "reduced
tolerance class")
B380EN02.DOC 5BOperating materials – Version 11 2-21

TruPunch 5000 Note
Oxidized, heavily oiled or scarred sheets can significantly reduce
the suction capacity of the suction cups of the SheetMaster.
¾ Only use workpiece surfaces with the following properties:

– Clean
– Dry
– Smooth
– Not heavily oiled.
Test workpiece ¾ Prepare two sheets for the machine test:

– 1000 x 1000 mm.
– USt 12.03 (DIN EN 10131).
– s = 2.5 mm.

5.4 Pallets for SheetMaster (optional)
Smooth operation of the SheetMaster during loading and unloading

requires pallets with a minimum height of 90 mm.
Tip
Use European standard pallets with a standard height of 150 mm.
5.5 Older tool cartridges
Stripper monitor The machine is equipped with a sensory stripper monitor. A light
sensor on the punching head is used to determine whether the
stripper is available.
If older cartridges are used, the light beam is interrupted by a
stripper arm on the cartridge. The cartridge must be ground using
the template which is delivered with the accessories.
If no opportunity to post-process the cartridges on site exists,
please contact TRUMPF.
Newer metal cartridges made from precision casting can be
recognized by their magnetic laminas which can be written on.
They are delivered with the machine and do not need to be post-
processed.
RTC cartridges (Rapid Tool Change) are not affected by this
measure.

Additional equipment, tools, material
• Template
• Belt grinder.
or
Grinding block.
Post-processing tool
cartridges
Template Fig. 19483
Marking out Fig. 19544
1. Mark out the tool cartridge using the template.

2. Grind the right side of the cartridge on either the belt grinder or
the grinding block.

5.6 New MultiTools and tapping tools
• The TruPunch 5000 uses new MultiTool- (2, 5 and 10 x) and

tapping tools.
Both are not compatible with the previous tools in the way they
are used, for example, with the TC 200 R, TC 500 R and TC 600.
Damage to stripper adapter by tool collision

¾ Do not use the previous MultiTools and tapping tools on the
TruPunch 5000.
Caution ¾ Do not use new MultiTools and tapping tools on old
machines.

6. Transport
The arrangements and transport of the system from the truck to its
final installation site need to be prepared and carried out.
In particular, gates, header heights, cable rack heights, ground
conditions for armored rollers etc. must be checked.
¾ Confirm the transport route to the installation position of the

machine before the machine is delivered, taking into account
the dimensions of the machine during the transport route.
Transport dimensions of components

TruPunch 5000 Length Width Height
mm mm mm
1
TruPunch 5000 (medium approx. 5600 approx. 2000 2230
format)
TruPunch 5000 (large format) approx. 6600 approx. 2000 2230 1
Switch cabinet 1300 1000 2150
Cooling unit 700 700 800
Table 2-16
TruPunch 5000 with Length Width Height

automation mm mm mm
SheetMaster (1305) 8600 2190 2750
SheetMaster (1305) with a 8600 2500 2750
Y-400 sorting axis (optional)
SheetMaster (1605) 8600 2291 2750
SheetMaster (1605) with a 8600 2500 2750
Y-400 sorting axis (optional)
SheetMaster (1605, plus) 10350 2450 2780
SheetMaster - switch cabinet 1300 1000 2170
GripMaster 1400 1600 1400
GripMaster (Plus) 2000 1800 1900
Support table with 3600 2000 1200
GripMaster (Plus)
Scissor table 1305 2600 1350 550
Scissor table 1605 3100 1600 550
ShearMaster (optional) incl. 2150 2060 1470
GripMaster and switch cabinet
Scrap conveyor (optional), 3270 2000 1050
2500 mm length
Table 2-17
1
Without transport girders.
2-26 6BTransport – Version 11 B380EN02.DOC

6.1 Measures to be taken by the customer
Note
The floor of the installation site must be designed to fulfill the
requirements (see section 2.2, p. 6).

• Crane truck (min. carrying capacity of 50 t) with.
– Shackles, C shape, nominal size 32 (DIN 82101).
– Usual chains (e.g. oval suspension link) and conveyor
belts.
• Gantry crane (min. carrying capacity of 20 t).
or
Armored rollers (min. carrying capacity of 10 t each).
– 1 steerable roller.
– 2 fixed rollers.
• At least two hydraulic hoisting jacks.
– Min. carrying capacity of 10 t.
– Min. adjustable height: ≤ 30 mm.
• Hoisting iron (2 m) and extension.
Machine delivery
1. Examine all components for damage in transit.

2. Record any visible damage in transit on the cargo note and
have it countersigned by the truck driver.
3. Report any hidden damage caused during transport to the
insurance company and to TRUMPF within 6 days.
B380EN02.DOC 6BTransport – Version 11 2-27

Unloading the machine from the truck

• Crane truck (min. carrying capacity of 50 t) with.
– Shackles, C shape, nominal size 32 (DIN 82101).
– Usual chains (e.g. oval suspension link) and conveyor
belts.
Suspended load
Entering the danger zone can result in serious injuries or
death.
Warning ¾ Observe the applicable safety regulations regarding the
handling of heavy loads.
¾ Never walk under a suspended load.
¾ Employ qualified technicians to transport the machine.
Note
A crane truck of greater carrying capacity must be used however, if
a larger lever arm is required due to the conditions on site.
85 mm
85 mm
mm
80
Eyebolt of the machine Fig. 24473

1 2 3
1 Shackle 3 Crane hook

2 Oval suspension link
Transport with gantry crane Fig. 24519
246 mm
110 mm
80mm
250 mm
Shackle Fig. 26516

The machine's front part is not made for lifting the machine.
This could cause severe damage.
¾ Use the eyebolts at the load suspension points to raise the
Warning machine, observing a chain minimum of 800 mm.
1 Eyebolt at front end, coming from 2 Eyebolts on the machine legs

machine leg
Transport regulation: lifting the machine over a threshold Fig. 39034
¾ Unload the machine using the crane truck while removing the
wooden girders from the machine feet as long as the machine
is hanging from the crane shackle.
TruPunch 5000 with ¾ Unload the SheetMaster only using the eyebolts which are
SheetMaster attached to the frame.

Transporting the machine to the installation
site

• Gantry crane (min. carrying capacity of 20 t).
or
Armored rollers (min. carrying capacity of 10 t each).
– 1 steerable roller.
– 2 fixed rollers.
• Forklift (carrying capacity min. 3 t).
Transporting the machine
1. Transport the machine into the factory hall on armored rollers

using the forklift.
2. To transport the machine to the installation site:
¾ Use gantry crane.
or
¾ Use armored rollers and a forklift.
Transporting accessory systems
¾ Transport the control cabinet with a forklift.

¾ Transport the cooling unit using forklift.
TruPunch 5000 with ¾ Transport the SheetMaster into the factory on armored rollers.
SheetMaster
¾ Transport the control cabinet of the SheetMaster with a forklift.

Installing the machine

• At least two hydraulic hoisting jacks.
– Min. carrying capacity of 10 t.
– Min. adjustable height: ≤ 30 mm.
Note
The machine may not be pushed on the ground when the air
cushion elements are installed.
1. When using armored rollers:

– Position the machine using a hoisting iron.
– Join the hydraulic hoisting jacks to the machine feet on
both sides.
– Raise the machine with the hydraulic hoisting jacks.
2. With standard installation on 4 wedge mounts:
– Push the wedge mounts under the machine feet, taking
care that the jackscrews on the wedge mounts are pointing
outwards.
3. In case of installation on four air cushion elements (optional):
– Install the air cushion elements under the rear machine
feet with the screws, taking care that the valves are
accessible.
– Install the air cushion elements under the front machine
feet with the screws, taking care that the valves are
accessible.

Chapter 3
Description
1. The machine concept .................................................... 3-4
2. Technical data................................................................ 3-7
3. The most important assemblies................................... 3-8

3.1 Machine frame ................................................................. 3-9
3.2 Punching head............................................................... 3-10
3.3 Coordinate guide with linear magazine ......................... 3-11
3.4 Drives............................................................................. 3-12
3.5 Part removal .................................................................. 3-13
4. Tools ............................................................................. 3-14

4.1 The tool system ............................................................. 3-14
4.2 Components of a tool set............................................... 3-16
Punch........................................................................ 3-16
Punch selection ........................................................ 3-18
Alignment ring........................................................... 3-20
Die ............................................................................ 3-20
Stripper ..................................................................... 3-22
4.3 Stripper selection ........................................................... 3-23
Table 1: Short, flat punch ......................................... 3-26

Table 2: Long, flat punch .......................................... 3-27
Continuation of table 2.............................................. 3-28
Table 3: Angle-sheared punch ................................. 3-29
Stripper selection examples ..................................... 3-30
4.4 Tool innovations............................................................. 3-33
Roller tools................................................................ 3-33
Roller deburring tool and deburring MultiTool .......... 3-35
TRUMPF MultiTools ................................................. 3-36
Tapping tools ............................................................ 3-41
Clean cutting with TRUMPF MultiShear................... 3-43
Press brake bending with the TRUMPF
MultiBend.................................................................. 3-44
Quick beading........................................................... 3-45
Engraving.................................................................. 3-45
Adaptive stroke calibration ....................................... 3-46
5. Maximum output tables............................................... 3-48

5.1 Calculation formulae ...................................................... 3-48
5.3 Punch............................................................................. 3-51
5.4 Dies................................................................................ 3-51
5.5 Table overview............................................................... 3-53
6. Stroke rate tables......................................................... 3-56

6.2 Table overview: TruPunch 5000 (medium format) ........ 3-57
Standard tool ............................................................ 3-57
Whisper tool.............................................................. 3-59
MultiTool ................................................................... 3-62
Forming tool.............................................................. 3-63
6.3 Table overview: TruPunch 5000 (large format) ............. 3-64
Standard tool ............................................................ 3-64
Whisper tool.............................................................. 3-66
MultiTool ................................................................... 3-69
Forming tool.............................................................. 3-70
7. Technical information: Automation ........................... 3-71

7.1 Automation made to measure ....................................... 3-71
7.2 Overview of automation ................................................. 3-72
7.3 Simple automation ......................................................... 3-73
SheetMaster ............................................................. 3-74
Loading table (TruPunch 5000 only) ........................ 3-78

GripMaster ................................................................ 3-79
ShearMaster (not TruPunch 3000) ........................... 3-81
7.4 Flexible manufacturing cell ............................................ 3-83
TruMatic 6000).......................................................... 3-84
Cart systems with travel rails.................................... 3-87
Cart system with toothed belt drive .......................... 3-89
Characteristic features.............................................. 3-90
SortMaster Box ......................................................... 3-91
SortMaster Pallet ...................................................... 3-92
7.5 Flexible manufacturing cell with TRUMPF compact
store ............................................................................... 3-94
7.6 Flexible sheet machining system................................... 3-96
7.7 Control system and administration for connection to
storage ........................................................................... 3-97
8. Control system technology ........................................ 3-98
9. Programming ............................................................. 3-100

9.1 Directly at the machine ................................................ 3-100
9.2 In the office .................................................................. 3-101
Defining machining: What is done automatically?.. 3-102
10. The most important options ..................................... 3-103

10.1 Active die ..................................................................... 3-104
10.2 Die spray lubrication .................................................... 3-105
10.3 Brush tables with loading and unloading aid ............... 3-106
10.4 Height-adjustable clamps ............................................ 3-107

1. The machine concept
The TruPunch 5000 stands for rapid, high-quality machining, a

high degree of automation and great productivity.
Equipped as it is with the newly developed active die, scratches
are now a thing of the past, while at the same time the forming
options available with the machine have been advanced.
Fig. 54425
The active die enables non-scratch machining because it moves

downward during the positioning of the sheet. In addition, the
danger of the die becoming interlocked with the formed areas has
been eliminated.
The active die acts like a second punching head with a stroke from
below, opening up new opportunities with respect to forming.
Special tools are available for the active die for larger-sized and
higher formings.
3-4 1BThe machine concept B380EN03.DOC

Programming With the aid of the TRUMPF programming software
TruTops Punch, your programmer generates the drawing, loads
the sheet and allows the machining to be defined automatically.
Loading Your machine operator loads the required tools into the linear
magazine. Afterwards, he places the sheet on the machine table –
manually or with the aid of the SheetMaster.
Machining Machining takes place at up to 1400 strokes/min. The

TruPunch 5000 punches or nibbles the desired contours in your
metal sheets of up to 8 mm in thickness. You can, for example,
form threads, mold link plates or produce endless beading at up to
maximum axis speed. The single station tool adapter is responsible
thereby for high dimensional accuracy. The necessary tool
changes take place at an average of 2.8 s (from one place to
another).
Part removal Your workpieces can be ejected directly into a parts container
through a parts flap 500 x 500 mm in size. Larger parts are
removed manually or with the aid of the SheetMaster.
Automation The automation concept of the TruPunch 5000 makes it possible to

expand your system all the way to full automation. Depending on
requirements, the machine can be automated from the
SheetMaster loading and unloading accessory all the way to a
connection with a storage system.
Process safety and accuracy The machine is equipped with a number of sensors which monitor
the different processes during machining. That offers you safety,
particularly in terms of unmanned production:
• The clamp sensor system monitors whether the clamps are
holding a sheet.
• The tools of the linear magazine are also monitored by
sensors:
– The correct height of the punch is calculated.
– The presence of punch, stripper and die is checked.
• The tool adapter on the punching head is equipped with
sensors:
– The presence of stripper and die is checked during tool
changes.
– A check is made to see whether an RTC or a metal tool
cartridge is being used. The acceleration is then
automatically adjusted.
– In addition, the stripper segment is checked for damage.
• The parts flap on the machine allows for part removal of parts
up to 500 x 500 mm. An air blast assist provides for additional
process consistency.
B380EN03.DOC 1BThe machine concept 3-5

The high degree of precision of the TruPunch 5000 is achieved by
means of various design measures which complement each other:
• FEM-calculated C-frame with a high degree of cross rigidity. A
high degree of rigidity directly affects the precision. The
following also applies for the tools: less tool wear, particularly
with off-center loads.
• FEM-calculated coordinate guidance.
• High degree of stiffness due to ISA guidance in the coordinate
guidance.
• Reduced heat generation due to water-cooled drive.
• Extremely narrow twisting play in the C-axis enables extremely
small clearances.
• With absolute zero backlash, the wear-resistant hydrostatic
ram guide ensures an exact alignment of punch and die.
3-6 1BThe machine concept B380EN03.DOC

2. Technical data
TruPunch 5000 TruPunch 5000

(medium format) (large format)
Workpiece weight Max. workpiece weight kg 200 230
Punching and presser foot Max. punching force kN 220 220
force
Max. presser foot force kN 20 20
Progr. presser foot force kN Approx. 4.5 - 20 Approx. 4.5 - 20
Active die Punching and forming force kN 220 220
2
Max. acceleration m/s 14 14
Max. stroke speed m/min 4 4
Travel range mm 35 35
Max. hit rates Punching pitch of 1 mm 1/min 1400 1200
Engraving 1/min 2800 2800
Max. joint speeds X axis m/min 100 100
Y axis m/min 60 60
Speed C axis 1/min 350 350
Linear magazine Number of linear magazine stations 21 25
Number of tools/clamps 18/3 21/4
Number of tools when using 18 – 180/2 21 – 210/2
MultiTool/clamps
Number of clamps 3/3 4/4
(standard/maximum)
Punching part removal Max. part size: mm 500 x 500 500 x 500
Punching parts flap (standard)
Cycle times Tool change time standard tool (from s 2.8 2.8
place to place)
Tool change time, MultiTool s 0.3 0.3
Accuracy Smallest possible increment. mm 0.001 0.001
Control system Color screen, TFT 12" 12"
Operating system, Windows XP XP
Dimensions and weights Working height without SheetMaster mm 1020 1020
Depth mm 5775 6693
Width mm 6500 7600
Approx. weight kg 13700 17300
Electr. and pneumatic Electr. power consumption, punching kW/h 13 13
consumption details
Machine:
Compressed air consumption ∅ Nm3/h 22.6 22.6
Max. compressed air consumption 48.5 48.5
SheetMaster:
Compressed air consumption ∅ Nm3/h 21.2 21.2
Max. compressed air consumption 90.5 90.5
Table 3-1
B380EN03.DOC 2BTechnical data 3-7

3. The most important assemblies
1 Coordinate guide 4 Linear magazine

2 Machine tables 5 Punching head
3 Machine body 6 Control panel
Fig. 54425
The TruPunch 5000 of course meets the basic safety and health
requirements of the EU Machinery Directive 98/37/EU. This is
confirmed by the EC declaration of conformity and the CE machine
identification.
3-8 3BThe most important assemblies B380EN03.DOC

3.1 Machine frame
The machine frame consists of a torsion-free, C-shaped welding

structure. The high degree of rigidity has a direct effect on the
dimensional accuracy of the workpieces. Any transverse forces are
compensated.
Thanks to the stiff machine frame and the hydrostatically
positioned ram, the service life of your tools is prolonged: the tool
is protected only if the press ram is perpendicular when it plunges
into the die.
The C-shaped machine frame Fig. 25888
B380EN03.DOC 3BThe most important assemblies 3-9

3.2 Punching head
Punching head Fig. 44438
The ram's electrohydraulic drive enables a stroke rate of up to

1400 strokes/min (TruPunch 5000, medium format). The stroke
and punching force are variable. Both are automatically set with
every punching stroke, depending on the tool, material and sheet
thickness.
Precise with low maintenance • The ram has its own NC-controlled axis that automatically
requirements adapts the starting and reversing points of the ram movements
to the sheet thickness. The regrind amount of the punch is
compensated by means of the tool length compensation unit.
• The wear-resistant, extremely long hydrostatic ram guidance
guarantees high dimensional accuracy and tool life.
• The single station tool adapter enables you to perform off-
center machining.
Variable tool rotation The rotation of the tool adapter with up to 5.5 revolutions/s permits
continuous rotation of all tools at any angle.

3.3 Coordinate guide with linear magazine
Coordinate guide with linear magazine Fig. 53105
The axes of the FEM-calculated coordinate guide are parallel to

the machine table. It moves in Y direction along with the machine
table.
The linear magazine is a combination of tool memory and tool
changer. It is integrated in the coordinate guide. The linear
magazine moves in X-direction along the guidance with the
clamped sheet. Through movement along the X- and Y-axes, the
sheet is positioned under the punching head.
Easy and quick tool loading The linear magazine offers magazine stations for tools and clamps
along the X-axis. The magazine stations can have variable loads:
• TruPunch 5000 (medium format): 18 tools and 3 clamps.
• TruPunch 5000 (large format): 21 tools and 4 clamps.
Further features are:

• Fast and simple tool loading using pre-equipped tool
cartridges.
• Central tool clamping is performed simultaneously for all tools
loaded in the linear magazine by pushing a button.
• The tools are arranged clearly and always within your
operator's view.
• The clamp and tool positions are checked automatically before
the program starts.

3.4 Drives
• All drives are digital three-phase current servomotors from

Siemens.
• The advantages of digital drives are:
• A long service life, even in extreme temperatures.
• No maintenance due to permanent magnet control.
Fig. 26178
High dimensional accuracy Digital drives are not affected by interference caused by electrical
fields. Pinions and racks interlocked at an angle improve the ability
to withstand stress and provide for a greater stiffness of the drive
system than straight toothing. They also make less noise.
High positioning speeds The low rotor inertia enables the highly dynamic acceleration
performance and the high positioning speeds.

3.5 Part removal
There are different strategies for removing workpieces. Of course,

you can also remove all parts by hand.
Quick and reliable • The finished parts are removed directly via the fixed chutes or
the programmable part flaps resulting in short push-out paths
and times.
• The parts reach the container already positioned under the
machine table.
• After release punching, parts with a size of up to 50 x 80 mm
are pushed out directly through a fixed chute.
• Parts with a size of up to 500 x 500 mm are removed through
the programmable parts flap. The separation of the parts can
often even be performed while the parts flap is open.
• Optionally, part removal can be monitored with sensors.
Programmable parts flap Fig. 26183
Scrap skeletons and waste strips are either removed manually or

automatically with the GripMaster (optional). As an alternative, the
scrap skeletons can be removed with the ShearMaster (optional)
and cut up in to handy pieces, no more than 400 x 100 mm in size.

4. Tools
4.1 The tool system
Easy tool loading The entire tool set is preloaded in a tool cartridge, outside the
machine. The cartridge then only needs to be inserted in the linear
magazine. Each tool set consists of a punch (1), alignment ring (2),
stripper (3) and die (4).
1 Punch 3 Stripper
2 Alignment ring 4 Die
Complete tool set Fig. 26198
Size groups The tools are available in three size groups, designated as 0, I, II.
Tools of the same size group only vary in the nominal range of
their cutter geometry but not in their design or clamping range.
3-14 4BTools B380EN03.DOC

Punch The clamping diameter is identical for all sizes.
Alignment ring The adapter diameter is identical for all sizes.

Alignment rings are available in three different versions:
size I, size II and those for separating punches and reinforced HSS
punches.
Stripper The adapter diameter is identical for all sizes.
Die Dies are available in two different sizes (size I and II). An
intermediate ring is necessary for size-I dies. The die is loaded
from the die plate.
Cartridge Regardless of the tool size, standardized tool cartridges are

available as RTC cartridges (Rapid Tool Change) or metal
cartridges.
Versatile tool range TRUMPF offers a wide range of standard and special tools:
• Punching tools for separating standard contours, such as
round, square, rectangular or oblong hole.
• Slitting tools for cutting round internal and external contours;
these include TRUMPF MultiCut and curved (banana) tools.
• TRUMPF MultiTools with 2, 5 and 10 punches.
• Forming tools for plastically deforming sheets, such as
beading, extrusions, thread, louver cutting or hinges.
• Special tools for non-scratch machining.
• Special tools for embossing and engraving.
• TRUMPF MultiBend for press brake bending.
• Roller tools.
• TRUMPF MultiShear for clean cutting

¾ Do not use the previous MultiTools and tapping tools on the
TruPunch 5000.
Caution ¾ Do not use new MultiTool and tapping tools on old machines
(exception: TC 2000 R).
B380EN03.DOC 4BTools 3-15

Tool selection criteria Machine type:
• Permissible sheet thickness.
• Punching capacity.
• Tool system.
• Maximum output tables.
Workpiece:
• Sheet thickness.
• Tensile strength.
Process:
• Punching
• Nibbling
• Cutting with slitting tools.
• Working with special tools: e.g. punching and pushing out,
punches with guided cutting edge, forming, tapping, MultiTool.
• Engraving and embossing.
4.2 Components of a tool set
Punch
The right punch for each Punches are made of high-speed steel (HSS) and are extremely
application resilient.
There are different punch versions for the tool:

• Single-part or multipart punches: the multipart punch consists
of a needle punch and a punch chuck. The needle punch is
simply replaced when it is worn out.
• Straight or angle-sheared: tools with angle-sheared punches
are called whisper tools. The use of whispertools reduces
noise by up to 50 %.
• Undamaged or coated: TICN-coated punches are
recommended specially for machining aluminum and stainless
steel to prevent cold welding and premature wear of the punch.

The machine can be equipped with new, longer punches. Flat
punches (needle punches too) are 3.5 mm longer than before.
Punches used on other TRUMPF machines can also be used.
• Regrinding: new long punches can be reground up to 6.5 mm
while observing the clearance angle and angle-sheared
punches (whispertools) can be reground up to 3 mm.
• Longer punches can also be used on a TC 500 R, TC 200 R or
TC 600 L if they have been reground more than 3.5 mm.
• Measuring tool length: the tool length is entered in the tool data
and processed. It corresponds to the dimension from the upper
edge of the alignment ring to the lower edge of the punch.
1 Tool length
Punch Fig. 45779
Compensation of the regrind There is a magnetic disk on the tool cartridge, which can be written
amount on with a washable felt-tip pen. The current tool length can be
noted down on it. The magnetic plate can also be attached to the
alignment ring if the punch with alignment ring was temporarily
taken out of the cartridge. The tool length information is thus
"saved" at the tool.

Punch selection
Structure
1 Punch chuck 2 Needle punch

Single-part and multi-part punch Fig. 19097
Cutting surface
h Height of the shear, max. 3 mm α Angle of the shear

Flat punch, whispertool and roof-shaped punch Fig. 19172
Advantages of whisper tools • Reduced punching force requirements for the same punch
dimension.
• Noise reduction.
• Particularly effective when machining high-tensile and tough
materials.

Punch dimensions of a tool
in new condition
1 Flat punch * Long, flat punch

2 Shear punch (Whispertool)
Punch dimensions Fig. 19501
Materials • High-power quick work steel (HSS) for high demands.

• HSS "oxidized" for highest demands.
• The material type is engraved on the top of the punch head:
e.g. code G for HSS.
Tool dimensions The tool dimensions are engraved on the side of the punch head,
e.g. 12 for a square tool with 12 mm long edges.

Alignment ring
Fig. 19505
The alignment ring fulfills the following functions:

• Transfer of the punching force onto the punch.
• Assignment of the angular position of the punch and fixation.
• Adaptation of various punch sizes.
• Holding the punch in the cartridge.
Die
Fig. 19503

h Height of the die h = 20 mm for size II
h = 18 mm for size I
Die Fig. 2275
h Height of the die h = 20 mm for size II

h = 18 mm for size I Reinforcement hv: 9 mm
Reinforced die Fig. 2276
Selection of the suitable die The selection of a suitable die also depends on the sheet thickness
to be machined. A larger clearance between the punch and die is
needed the more the sheet thickness increases.
The die geometry to be selected is calculated as the sum of the
punch geometry plus the value 0.2 x sheet thickness (s).
For round tools, the diameter must be used in the formula for the
punch geometry. The following is yielded:
ØDie = ØPunch + (0.2•s)
Other geometries should be treated accordingly.

Stripper
Fig. 19504
The stripper can perform two functions:
Presser foot function When punching with an active presser foot, the stripper rests on
the sheet while the punching stroke is performed. The sheet is
pressed on to the die underneath. This improves evenness.
Machining with an active presser foot in combination with a long
tool (tool length: 37.8 mm) is performed almost as quickly as in
operation with a passive presser foot.
The stripper assumes this presser foot function even when
repositioning.

Stripper construction types
A Old stripper B New stripper

Stripper construction types Fig. 45477
Risk of collision between the old stripper and the workpiece.

Old stripper versions, such as those used on the TC 260,
must not be used on the TruPunch 5000. Strippers must
have a bevel like those used on the machines TC 200R, TC
Caution
500R and TC 600 L and TC 2000 R.
¾ Only use the new strippers with bevel.
Spring-loaded push-out strippers are recommended for pushing

out thin sheets.
4.3 Stripper selection
The selection of the stripper dimension depends on 1):

• The (programmed) sheet thickness.
• The size of the shape to be punched.
• The tool length of the punch (new, reground).
– The tool length is defined as the dimension from the upper
edge of the alignment ring to the cutting edge.
1
When non-scratch machining is selected, the working height is increased
by 1 mm. Therefore, when selecting a stripper, the column in the stripper
selection table with the next highest sheet thickness must be consulted (for
LDP and UDP offset = 0).

1 Tool length
Fig. 45779
Special punch The stripper is selected according to the following criteria when
using special punches:
• With special-purpose punches with an outer circle diameter <
10.5 mm, the stripper must be selected from the line "Punch
10.51-30.0" in the stripper selection table.
• With special-purpose punches with outer circle diameters
larger than 10.5 mm, the stripper must be selected according
to the outer circle diameter of the special punch.
1 Punch 3 Die
2 Stripper 4 Collision
Collision between punch and stripper Fig. 44970

Collision between punch and stripper/stripper adapter (see
Fig. 44970).
If the stripper dimensions listed in the following stripper
Caution selection tables are not complied with (for non-scratch
machining as well), the strippers and, in the worse case, the
stripper adapters will be damaged! Further damage may
result!
¾ Therefore always consult the stripper selection tables for first
use, after regrinding, after changing the sheet thickness and
on selecting "non-scratch machining"!
The essential value for selecting the stripper is the outer circle
diameter of the punch. Example: rectangular punch.
1 Outer circle diameter of punch 3 Punch length

2 Punch width 4 Example: Rectangular punch
Fig. 44853

Table 1: Short, flat punch
A: Tool length, new condition

B: Tool length, ground
Table 3-2

Table 2: Long, flat punch

B: Tool length, ground 3 mm
Table 3-3

Continuation of table 2

B: Tool length, ground 6 mm
Table 3-4

Table 3: Angle-sheared punch

B: Tool length, ground
Table 3-5

Stripper selection examples
Example 1
Task Find the suitable stripper for the following punches:
• Short, flat new punch.
• Punch diameter 12 mm.
• Tool length 34.3 mm.
• Sheet thickness 6 mm.
1 Stripper 4 Sheet thickness

2 Wall thickness 5 Plunge depth
3 Air gap
Fig. 44855
Steps 1 to 5 for the selection
Fig. 45782en
Solution The correct stripper according to the table ( ) is equivalent to a

punch diameter of +1 mm, therefore Ø 13 mm or more.

Example 2
• Short, flat punch, maximum regrind.

3 Air gap 6 Max. regrind
Fig. 44837
Fig. 45783en
Solution According to the table, the correct stripper dimension is 31 mm or

more.

Example 3
• Short, flat punch, maximum regrind.
• Non-scratch machining.

3 Air gap 6 Max. regrind
Fig. 44837
Fig. 45859en

Solution Note
For non-scratch machining, 4+1 mm must be selected for the sheet
thickness in step 3.
Taking non-scratch machining into account, the correct stripper

dimension is 31 mm or more according to the table.
4.4 Tool innovations
Roller tools
Rolling instead of punching! Do you produce many endless beads or folds? Or long cuts? Then
in the future you will no longer be punching, but rather rolling. For
this type of machining in the field of sheet metalwork up to
maximum 2.5 mm (depending on material), beading tools are the
alternative to normal forming tools.
With roller tools, the sheet is not machined by consecutive
punching strokes, but rather by the sheet moving between steel
rollers in the punch and die.
Endless bead produced with the roller beading tool Fig. 36984

Using the beading tools, you can work up to maximum axle speed
(depending on sheet thickness and machining direction). The
machining time is shorter than those associated with the use of
other tools, you save on production costs. In addition, beading
tools are practically noiseless during operation!
The range of roller tools includes the following types of tools:

• Using the beading tool, you can use endless beading to
stiffen large sheets, for example.
• Using the roller folding tool, you produce continuous foldings.
• Using the roller cutting tool, long parting cuts as well as
unusual contours are ready in a flash.
• With the roller pinching tool, the sheet is not machined by
consecutive punching strokes, but rather by having the sheet
traverse between 2 steel rollers located in the punch and die.
• The maximum burr that arises during punching on the sheet is
pressed down at axis speed during roller deburring.
Roller beads Roller folding Roller cutting Roller Roller deburring

pinching
Sheet thickness:
Mild steel mm 0.8–2.5 0.8–2.0 0.8–2.0 0.8–2.0 0.8–2.5
Stainless steel 0.8–1.5 0.8–1.5 0.8–1.5 0.8–1.5 0.8–2.5
Aluminum 0.8–2.5 0.8–2.5 0.8–2.5 0.8–2.5 0.8–2.5
Standard forming mm – 1.5/3.0 – – –
height
Radius mm 20 – 45 500 >20 (Roller
deburring tool)
<20 (Deburring
MultiTool)
Roller tools Table 3-6

Roller deburring tool and deburring
MultiTool
Roller deburring tools Fig. 48252
Previously, it has above all been coated sheets and sheets with
formed areas that were manually deburred in a subsequent
processing step. The procedure offered by TRUMPF makes it
possible for you to accomplish all of the machining stages on the
punching machine itself and reduces the run-through time.
Two tools are available for you for deburring:

• Roller deburring tool with specially formed embossing roller
below:
– Suitable for radiuses >20 mm.
– When deburring with the aid of the roller deburring tool, the
burr is removed without chips and at axis speed (up to
100 m/min) on the TruPunch 5000 and the edge is
chamfered (approximately 0.1 mm).
• Deburring MultiTool with different embossing contours (die
inserts):
– Suitable for radiuses <20 mm and for the removal of
stationary remaining contours.
– With the Deburring MultiTool, sheets are deburred with a
single stroke or in nibbling operation and the edge is
chamfered as well (approximately 0.1 mm).
– Remaining contours can be removed without effort.

Application Used with steel, stainless steel and aluminum, sheet thickness
0.8–2.5 mm (standard).
Programming Programming with TruTops Punch.
Advantages • You can produce qualitatively outstanding parts in a clamping

operation when working in conjunction with MultiShear, which
is also important for subsequent tasks such as welding, for
example (quality of the seam for overlapping sheet metal
parts).
• The better edge quality leads to fewer injuries during parts
handling.
TRUMPF MultiTools
MultiTools have been developed for the TruPunch 5000, which:

• Can machine sheet thicknesses of up to 4.5 mm.
• Contain more individual tools than previously.
• Are characterized by improved regrinding capabilities.
• Enable simplified tooling by means of the integrated set-up aid.

¾ Do not use the previous MultiTool tools on the
TruPunch 5000.
Caution ¾ Do not use new MultiTools on old machines (exception:
TC 2000 R).
Previous MultiTools must not

be used on the
TruPunch 5000.
4-station MultiTool 6-station MultiTool

12-station embossing MultiTool
Max. sheet thickness • Mild steel: 4.5 mm (with active presser foot). 4 mm (without
active presser foot).
• Stainless steel: 3.0 mm.
Max. regrind amount • 2-station MultiTool:

– Punch: 0.5 mm.
– Die: 1 mm.
• 5-station MultiTool:
– Punch: 0.5 mm.
– Die: 1 mm.
• 10-station MultiTool:
– Punch: 0.5 mm.
– Die: 1 mm.

2-station MultiTool:
Fig. 38833
Max. punch diameter • D = 24.5 mm.
Die version • Two recesses according to the punch geometry.
Stripper version • Contour stripper: 2 cut-outs corresponding with the punch

geometry +0.5 mm clearance.

5-station MultiTool
Fig. 26150
Die version • 5 single inserts.
Stripper version • Standard stripper: 5 bore holes with D = 17 mm.

• Contour stripper: 5 cutouts according to the punch geometries
+ 0.5 mm (circumferential).

10-station MultiTool
Fig. 26149
Die version • 10 single inserts.
Stripper version • Standard stripper: 10 bore holes with D = 11.5 mm.

• Contour stripper: 10 cutouts according to the punch
geometries + 0.5 mm (circumferential).
Detailed information about MultiTools on the TruPunch 5000 can

be found in "Technical information: MultiTool".

Tapping tools
Function Tapping tools can be used to insert threads into even sheets and
extrusions without chips.
Structure
1 Die 4 Guide spindle

2 Spindle nut 5 Tool housing with anti-twist
3 Thread former device
Fig. 5623

The new tapping tool, designed for the TruPunch 5000, consists of
a tool housing with integrated gearing in which the guide spindle is
fitted. The guide spindle holds the thread former (M2.5 – M10). The
guide spindle, with the thread former, is fixated on the housing by
the spindle nut.
For each thread size there is a corresponding cartridge (guide
spindle with tapping tool and spindle nut). The die complements
the tool set.

¾ Do not use the previous tapping tool on the TruMatic 5000.
¾ Do not use new tapping tools on old machines (exception:
Caution TC 2000 R).
The previous tapping tool

must not be used on the
TruPunch 5000.
New tapping tool for the

TruPunch 5000.
Detailed information about tapping on the TruPunch 5000 can be

found in "Technical information: Tapping".

Clean cutting with TRUMPF MultiShear
Background When conventional punching tools are used to separate parts, this
generally leads to nibble marks which can spoil the appearance,
particularly of visible edges.
TRUMPF decided to deal with this issue and has developed the
MultiShear, a tool for clean cutting. You can use it to create cutting
edges without marks - just like laser cutting edges.
The advantages and features are:
• Visually perfect clean cutting edges.
• Machining of outer and inner contours.
• Application of MultiShear at any angle.
• Suitable for common cuts. The quality of the separating cuts is
perfect on both sides.
• Max. separating speed: 12 m/min.
• Max. material thickness: 3.0 mm.
Fig. 31266
Programming system MultiShear is supported by the TruTops Punch programming

system.
Further information on the new MultiShear can be found in

"Technical telegram: New tools".

Press brake bending with the TRUMPF
MultiBend
Background Up to now, whenever press brake bending was necessary on a

punched part, this production step had to be performed at a
distance to the machine.
With MultiBend, TRUMPF has developed a tool that enables press
brake bending on a punching machine. This means lower costs
and an expansion of your parts range.
The features are:
• Bending operations are now possible on outer and inner
contours.
• Bending angle: 90°.
• Bend height: 25 mm.
• Bend length: 55 mm and 20 mm.
• Material thickness range: 0.5 - 2 mm.
1 Punch 3 Spring-loaded ejector

2 Rotary bending insert
Fig. 26360
Programming system MultiBend is supported by the TruTops Punch programming

system.
Further information on the new MultiBend can be found in

"Technical Telegram: New tools".

Quick beading
Function The quick beading machining type is optionally available on the

TruPunch 5000. It is used to produce endless beads. From the
"quick beading" working position, the endless bead is formed with
a beading tool oscillating at a high stroke rate. The stroke rate
reaches up to 2800 min-1.
Prerequisite The engraving option is a prerequisite for quick beading.

Further information on quick beading can be found in "Technical
telegram: News on the TC 2000 R".
Detailed information on TRUMPF punching tools can be found in

"Technical information on punching tools" and on the "Electronic
Punch Catalog" CD-ROM.
Engraving
Fig. 54654
Label sheets without A wide range of characters can be engraved into the sheets. A
chipping pressed-in spring-loaded needle pushes the material away without
causing chipping.

The tool is suitable for engraving on the sheet surfaces of the
following materials:
• Steel
• Aluminum
• Stainless steel.
(other materials upon request).
Advantages • Marking of parts:

− With numbers, letters, symbols.
− With different lettering heights and widths.
− With a variety of character sets.
− With special characters.
− With logos and any contours required (sample).
• No single strokes, ensuring quality and a time advantage.
• Low noise generation.
Characteristic features • Prerequisite for the utilization of the engraving tool is the
engraving option.
• Material thickness 1.0 - 8.0 mm, comply with permissible
material thickness of the machine.
• Engraving depth and line width: 0.2 mm.
Adaptive stroke calibration
Constant embossing depth TRUMPF is the only company in the world offering adaptive stroke
and exact formed sections calibration on punching machines. A constant embossing depth
and exact formed sections are thus possible and are independent
of sheet thickness tolerances.
Problem: Sheet thickness Everyone knows the problem that sheet thicknesses vary in
tolerances practice. A sheet with a thickness of 2 mm may vary by up to
±0.13 mm according to EN 10131. This affects the processing
result and the accuracy of the produced sheet metal parts. Imprints
and identification marks are incorporated more or less deeply into
the sheet and the ratios change for the forming as well.
Compensating for sheet TRUMPF has found a solution for this problem with adaptive stroke
thickness tolerances calibration. It consists of:
• Calibration tool.
• Upgraded ram control software.

Extremely high accuracy – As a part of this new function, the thickness of the present sheet is
from the first part on measured in only 2.5 s (plus tool change time) to an extremely high
accuracy of ±0.03 mm and the ram stroke is adjusted to the current
thickness measured. Sheet thickness tolerances are thus
compensated automatically.
Calibration tool Fig. 40321
Further information concerning Adaptive Stroke Calibration can be

found contained in "Technical telegram: Adaptive Stroke
Calibration".

5. Maximum output tables
5.1 Calculation formulae
The maximum permissible dimensions for round and square tools,

with and without shears, for four tensile strengths and various
sheet thicknesses can be taken from the maximum output tables.
For intermediate values of the sheet thickness and tensile strength,
either the next-lowest table value should be taken or the following
formulas should be used to calculate the workpiece dimensions.
Note
• Using angled tools (Whispertools) reduces the punching force
up to 72 % (sheet thickness 1 mm).
• Tools with roof shape also reduce the punching force, but not
as much as whispertools.
Maximum diameter for round

tools
dmax Maximum tool diameter, round (mm)

p punching force (N)
s sheet thickness (mm)
Rm tensile strength (N/mm2)
x shearing factor (in tools without shear = 1)
Table 3-7
Maximum edge length for

square tools
amax Maximum edge length, square) (mm)

Table 3-8
Maximum cutting
circumference for tools of
any shape or cluster
punching tools without
shears Lmax Maximum cutting circumference (mm)
Table 3-9
3-48 5BMaximum output tables B380EN03.DOC

5.2 Influencing factors
The maximum output tables are applicable to metallic materials. A

high level of strain hardening and hence an increase in the
required punching force should be taken into account in particular
when punching non-ferrous materials.
The values specified in the maximum output tables are

recommended values which are influenced among others by the
following factors:
• The sheet thickness can have tolerances of up to +18 %
upwards according to DIN EN 10131/10029/10051.
• The tensile strength can reach up to +12.5 %, in accordance
with DIN EN 10130.
• The reduction of the air gap between the punch and the die
from 10 % to 5 % of the sheet thickness increases the required
punching capacity by about 4 %.
• Lubrication of the workpiece reduces friction.
• The shear factor is influenced by the material properties.
• The sharpness of the punch.
• Damage and cutouts for the cutting edge of the punch.
Note
In practice, this means that if all the unfavorable factors are
multiplied with each other, then only approx. 70 % of the given
values should actually be applied.
B380EN03.DOC 5BMaximum output tables 3-49

p Punching force s Sheet thickness Symbol =
Influence of punch geometry and sheet thickness on the punching force Fig. 45848
The smaller the sheet thickness is, the greater the effectiveness of
angled tools is (cf. beam height). Using angled tools not only
reduces the punching force but also relieves both the worker and
the machine.

5.3 Punch
When using standard punches or punches with reinforced

shoulder, the maximum round and square punches that may be
used are as follows:
Punch shape Standard punch Punch with

reinforced
shoulder
Round: dmax mm 76.2 42.0
Square: amax mm 50.8 30.0
Table 3-10
5.4 Dies
Dies are available up to the following maximum sizes.
Die shape Standard dies Reinforced dies

Round: dmax (mm) 77.0 62.0
Square: amax (mm) 52.0 43.0
Table 3-11
a Side length of the square cutout d Inside diameter of the die

Standard die Fig. 45903

a Side length of the square cutout V Degree of amplification
d Inside diameter of the die
Reinforced die Fig. 45904
Size Die version Round d Square a Maximum

punching
mm mm capacity
kN
II Standard 32.01 - 77.0 22.01 - 52.0 180
II Reinforced 32.01 - 62.0 22.01 - 43.0 180
I All Up to 32.0 Up to 22.0 250
Maximum punching forces Table 3-12

5.5 Table overview
The table values specify the maximum dimensions of the punches

of round and square tools, depending on the sheet thickness and
tensile strength. The maximum tool dimensions in the "with"
column only apply to tools with original shears ("whisper tools").
This also applies to the shear factor.
Note
Row-by-row processing is strongly recommended for a sheet
thickness of 8 mm and a high degree of punching up!
Maximum capacity table for Sheet Shear factor Round Square

tensile strength thickness x d in mm a in mm
Rm = 200 N/mm2 s in mm
With without With without
1.0 3.5 76.2 76.2 50.8 50.8
1.5 2.66 76.2 76.2 50.8 50.8
2.0 2.25 76.2 76.2 50.8 50.8
2.5 2 76.2 76.2 50.8 50.8
3.0 1.83 76.2 76.2 50.8 50.8
3.5 1.71 76.2 76.2 50.8 50.8
4.0 1.62 76.2 76.2 50.8 50.8
5.0 1.5 76.2 63.7 50.8 50.0
1
6.0 1.41 74.8 62.0 50.8 41.7
1 1
8.0 1.31 62.0 48.6 40.9 38.21
Table 3-13
1
With reinforced die.

Maximum capacity table for
Sheet Shear factor Round Square
Rm= 400 N/mm2 s in mm
1.0 3.5 76.2 76.2 50.8 50.8
1.5 2.66 76.2 76.2 50.8 50.8
2.0 2.25 76.2 76.2 50.8 50.8
2.5 2 76.2 63.6 50.8 50.0
3.0 1.83 76.2 53.0 50.8 43.01
3.5 1.71 76.2 55.51 50.8 43.01
1
4.0 1.62 64.5 48.6 50.6 38.21
5.0 1.5 58.3 1 38.9 2 43.01 30.61
6.0 1.41 45.71 32.42 35.91 25.52
8.0 1.31 31.82 24.32 25.02 19.12
Table 3-14

Rm = 600 N/mm2 s in mm
1.0 3.5 76.2 76.2 50.8 50.8
1.5 2.66 76.2 70.7 50.8 50.8
1
2.0 2.25 76.2 62.0 50.8 43.01
2.5 2 76.2 51.81 50.8 40.71
3.0 1.83 64.7 43.21 50.8 34.01
3.5 1.71 62.01 37.02 49.81 29.12
4.0 1.62 52.51 32.42 41.31 25.42
5.0 1.5 38.92 25.92 30.61 20.42
2 2 2
6.0 1.41 30.5 21.6 23.9 17.02
8.0 1.31 21.22 16.22 16.72 12.72
Table 3-15
1
With reinforced die.
2
With reinforced die and punch with reinforced shoulder.

Rm= 800 N/mm2 s in mm
1.0 3.5 76.2 76.2 50.8 50.8
1
1.5 2.66 76.2 64.8 50.8 43.01
2.0 2.25 76.2 48.61 50.8 38.21
2.5 2 63.7 38.92 50.0 30.61
3.0 1.83 59.31 32.42 46.61 25.52
3.5 1.71 47.51 27.82 37.31 21.82
4.0 1.62 39.42 24.32 31.01 19.12
2 2 2
5.0 1.5 29.1 19.5 22.9 15.32
6.0 1.41 22.92 16.22 18.02 12.72
8.0 1.31 15.92 12.22 12.52 9.52
Table 3-16

6. Stroke rate tables
6.1 Influencing factors
The achieved stroke rate depends on the following functions:

• Axis concerned.
• Distance between the hole centers.
• Sheet thickness s.
• Punching force.
• Workpiece weight.
• Regrind length.
• Use of shear-angled tools.
• Use of special punching functions.
The table values have been determined by experiment and vary to

a certain extent.
3-56 6BStroke rate tables B380EN03.DOC

6.2 Table overview:
TruPunch 5000 (medium format)
Standard tool
Parameters • Axis speed: X = 100 m/min/Y = 60 m/min.

• Flat tool.
• Workpiece size: 1250 mm x 2500 mm.
X axis Sheet thickness in 1 2 4 8

mm
Workpiece weight 25 50 100 200
in kg
Acceleration in 20 20 20 10
m/s2
Axis jolt in m/s3 3500 1000 540 300
Pitch in mm Strokes/min
1 1200 931 637 409
5 898 670 485 366
10 736 574 418 323
25 556 461 342 266
50 437 371 295 225
100 328 295 242 183
200 241 223 195 145
500 137 128 119 99
1000 79 77 71 65
Table 3-17
B380EN03.DOC 6BStroke rate tables 3-57

Y axis Sheet thickness in 1 2 4 8
mm
in kg
m/s2
Axis jolt in m/s3 400 400 340 200
1 827 814 599 409
5 575 569 447 345
10 479 472 382 300
25 366 365 312 238
50 292 290 255 191
100 225 223 202 149
200 162 162 149 114
500 87 87 84 71
1000 49 49 48 44
Table 3-18

Whisper tool


mm
in kg
m/s2
Axis jolt in m/s3 3500 1000 540 300
1 751 656 506 342
5 682 532 437 340
10 584 470 385 301
25 461 393 320 253
50 376 327 276 216
100 295 264 231 177
200 223 207 187 141
500 130 124 117 97
1000 77 75 72 64
Table 3-19

mm
in kg
m/s2
Axis jolt in m/s3 400 400 340 200
1 635 603 506 342
5 476 456 409 318
10 409 393 352 280
25 324 316 291 223
50 264 258 241 182
100 208 204 193 144
200 153 151 145 111
500 85 84 82 69
1000 48 48 48 43
Table 3-20

Standard tool with active presser foot

• Flat tool.

mm
in kg
m/s2
Axis jolt in m/s3 3500 1000 540 300
1 554 501 404 295
5 544 443 339 253
10 483 398 306 231
25 394 340 263 203
50 331 288 233 176
100 266 239 200 148
200 206 192 166 123
500 124 119 108 86
1000 75 73 68 60
Table 3-21

mm
in kg
m/s2
Axis jolt in m/s3 400 400 340 200
1 518 499 402 295
5 409 401 327 248
10 357 352 290 224
25 291 287 248 186
50 241 239 211 156
100 194 192 173 128
200 145 143 133 102
500 82 82 78 66
1000 48 48 46 42
Table 3-22

Long standard tool with active presser foot

• Flat tool.

mm
in kg
m/s2
Axis jolt in m/s3 3500 1000 540 300
1 829 694 477 326
5 680 537 387 280
10 584 473 342 253
25 462 395 289 219
50 374 326 257 190
100 294 266 214 158
200 222 207 177 129
500 130 125 113 91
1000 77 75 70 62
Table 3-23

mm
in kg
m/s2
Axis jolt in m/s3 400 400 340 200
1 640 605 460 326
5 479 459 365 269
10 412 395 321 240
25 326 316 268 198
50 264 258 226 164
100 208 204 182 133
200 153 151 139 105
500 85 84 80 67
1000 48 48 47 42
Table 3-24

MultiTool

X axis Sheet thickness in 1 2 4

mm
Workpiece weight 25 50 100
in kg
Acceleration in 20 20 20
m/s2
Axis jolt in m/s3 3500 1000 540
1 1093 836 603
5 846 632 470
10 703 529 410
25 532 447 337
50 422 360 289
100 320 288 241
200 238 221 193
500 135 130 120
1000 79 76 73
Table 3-25
Y axis Sheet thickness in 1 2 4

mm
Workpiece weight 25 50 100
in kg
Acceleration in 10 10 10
m/s2
Axis jolt in m/s3 400 400 340
1 812 732 575
5 571 528 435
10 475 447 373
25 365 347 305
50 290 279 252
100 224 218 200
200 162 158 148
500 87 86 83
1000 48 48 48
Table 3-26

Forming tool

• Optimized forming height: 37 mm.

mm
in kg
m/s2
Axis jolt in m/s3 3500 1000 540 300
1 383 352 302 262
5 344 306 262 228
10 318 284 242 209
25 277 253 214 184
50 244 223 194 163
100 206 194 171 139
200 169 161 144 116
500 109 106 99 85
1000 69 67 65 58
Table 3-27

mm
in kg
m/s2
Axis jolt in m/s3 400 400 340 200
1 334 331 295 257
5 285 280 252 219
10 258 257 231 200
25 222 220 202 170
50 192 190 177 144
100 161 159 150 120
200 125 124 119 96
500 75 75 73 63
1000 45 44 43 39
Table 3-28

6.3 Table overview: TruPunch 5000 (large
format)
Standard tool

• Flat tool.
• Workpiece size: 1500 x 3000 mm.

mm
Workpiece weight in 36 72 144 288
kg
Acceleration in m/s2 18 18 15 4.5
3
Axis jolt in m/s 2000 1000 400 200
1 1012 867 570 316
5 770 633 437 316
10 641 548 380 289
25 489 440 309 226
50 388 355 263 181
100 298 280 218 143
200 226 214 173 108
500 131 127 112 74
1000 78 76 70 52
Table 3-29

mm
in kg
Acceleration in 9 9 7.5 3
m/s2
Axis jolt in m/s3 400 350 300 200
1 768 713 542 316
5 548 506 409 316
10 456 428 356 271
25 350 334 284 204
50 277 269 230 161
100 214 208 178 124
200 157 152 137 92
500 86 85 79 61
1000 48 48 47 40
Table 3-30

Whisper tool


mm
in kg
Acceleration in 18 18 15 4.5
m/s2
Axis jolt in m/s3 2000 1000 400 200
1 722 632 487 264
5 589 502 392 264
10 513 443 346 264
25 404 369 288 212
50 337 309 247 171
100 266 249 206 137
200 207 196 166 105
500 125 121 109 71
1000 75 73 69 52
Table 3-31

mm
in kg
m/s2
Axis jolt in m/s3 400 350 300 200
1 587 542 481 264
5 447 417 374 264
10 385 361 326 252
25 308 293 266 193
50 251 241 217 154
100 198 190 171 119
200 146 143 132 90
500 83 81 78 60
1000 48 48 46 39
Table 3-32

Standard tool with active presser foot

• Flat tool.

mm
in kg
m/s2
Axis jolt in m/s3 2000 1000 400 200
1 580 516 336 237
5 494 424 318 231
10 437 383 288 214
25 361 326 244 177
50 304 278 215 144
100 245 229 183 121
200 195 183 151 94
500 120 116 102 67
1000 73 71 67 49
Table 3-33

mm
in kg
m/s2
Axis jolt in m/s3 400 350 300 200
1 494 457 334 237
5 391 364 304 229
10 344 323 273 203
25 280 266 228 162
50 233 222 192 134
100 185 179 157 106
200 141 137 122 82
500 81 79 74 56
1000 47 47 45 37
Table 3-34

Long standard tool with active presser foot

• Flat tool.

mm
in kg
m/s2
Axis jolt in m/s3 2000 1000 400 200
1 694 589 423 285
5 566 475 347 250
10 500 423 310 225
25 401 356 261 184
50 331 299 228 155
100 263 243 192 124
200 204 192 158 98
500 124 120 105 68
1000 75 73 67 50
Table 3-35

mm
in kg
m/s2
Axis jolt in m/s3 400 350 300 200
1 570 513 414 285
5 436 399 331 243
10 380 352 295 216
25 302 284 243 170
50 247 235 201 139
100 195 187 163 109
200 145 141 126 85
500 82 81 75 57
1000 48 47 45 38
Table 3-36

MultiTool

X axis Sheet thickness in mm 1 2 4

Workpiece weight in kg 36 72 144
2
Acceleration in m/s 18 18 15
3
Axis jolt in m/s 2000 1000 400
1 964 806 547
5 735 605 428
10 618 527 370
25 475 425 304
50 380 347 258
100 295 274 214
200 223 211 171
500 130 126 112
1000 77 75 70
Table 3-37
Y axis Sheet thickness in mm 1 2 4

Workpiece weight in kg 36 72 144
2
Acceleration in m/s 9 9 7.5
3
Axis jolt in m/s 400 350 300
1 736 680 527
5 532 491 400
10 447 418 347
25 343 327 280
50 274 263 226
100 211 204 179
200 155 151 135
500 85 84 79
1000 48 48 47
Table 3-38

Forming tool

• Optimized forming height: 37 mm.

mm
in kg
m/s2
Axis jolt in m/s3 2000 1000 400 200
1 356 334 283 244
5 320 294 246 209
10 296 274 227 191
25 258 243 200 160
50 228 216 180 138
100 193 184 157 114
200 160 154 132 91
500 105 104 93 66
1000 67 67 63 48
Table 3-39
Y axis Sheet thickness in mm 1 2 4 8

Workpiece weight in kg 36 72 144 288
2
Acceleration in m/s 9 9 7.5 3
3
Axis jolt in m/s 400 350 300 200
1 320 310 277 244
5 274 263 238 204
10 250 241 218 184
25 214 207 189 150
50 184 180 162 125
100 154 150 137 102
200 122 120 110 79
500 74 73 69 55
1000 44 44 42 37
Table 3-40

7. Technical information: Automation
7.1 Automation made to measure
The attached Technical information documents the automation

concept of the following TRUMPF punch and multi-purpose
machines: TruPunch 3000, TruPunch 5000, TruMatic 3000,
TruMatic 6000. The punch or multi-purpose machine as always
forms the core of the system, which can be expanded modularly
according to requirements.
Example Fig. 47680
Configuration stages for any • Automatic loading and unloading of raw sheets and finished
requirements workpieces with SheetMaster and GripMaster.
– Extendible with double carts, SortMaster Box and
SortMaster pallet for the sorted depositing of finished
workpieces.
• Breaking up the scrap skeleton with the ShearMaster.
• External ToolMaster tool memory with 40 or 70 additional tool
stations.
• Connection to storage with TRUMPF compact store.
B380EN03.DOC 7BTechnical information: Automation 3-71

7.2 Overview of automation
5
2 4
1
1 Raw sheet loading with SheetMaster 4 Removing small parts in the SortMaster Box
2 Unloading finished workpieces with SheetMaster and 5 Unloading scrap skeletons with GripMaster or
depositing on the SortMaster Pallet unloading and shredding scrap skeletons with
3 Setting up 40 or 70 additional tools with ToolMaster ShearMaster
6 Operating the unit
Example: Material flow to a TruPunch 5000 Fig. 47826
What goes with what? TruPunch 3000 TruPunch 5000 TruMatic 3000 TruMatic 6000
(medium format)
SheetMaster x x x x
Double cart x x x x
SortMaster Box x x x x
SortMaster Pallet x x x x
GripMaster x x x x
ShearMaster - x x x
ToolMaster (40/70) - x - x
TRUMPF x x x x
compact store
Loading table - x - -
Storage system x x x x
Table 3-41
3-72 7BTechnical information: Automation B380EN03.DOC

7.3 Simple automation
1 Basic machine 4 SheetMaster

2 Loading station 5 GripMaster or ShearMaster
3 Unloading platform
Example Fig. 47822
The access solution consists of the basic machine with automation

of the loading and unloading processes in connection with a
loading station and an unloading platform.
Components • Loading station for taking up raw sheets.

• SheetMaster for the automatic loading and unloading of the
basic machine with raw sheets and/or finished workpieces.
• GripMaster for unloading scrap skeletons and waste strips or
ShearMaster for unloading and the shredding of scrap
skeletons and waste strips.

• Unloading platform for sorting finished workpieces.
• TruTops Punch is the programming system.
• The system is controlled by means of production plans.
SheetMaster
Function The SheetMaster is used for the automatic loading and unloading
of raw sheets and finished workpieces. It forms a unit together with
the GripMaster or ShearMaster.
5
4
3
2
1 Loading station with expanding magnets 4 Suction carriage

2 Unloading platform 5 Suction frame
3 Suction cup
Example Fig. 47823

TruPunch TruMatic
3000 5000 3000 6000
Max. dimensions of mm 2500 x 2500 x 3000 x 4000 x 2500 x 2500 x 3000 x
raw sheets and 1250 1250 1500 1500 1250 1250 1500
processed
workpieces
Max. sheet mm 6.4 8 8 8 6.4 8 8
thickness
Maximum permitted kg 160 200 285 285 160 200 230
sheet weight
Min. part size:
Load mm 600 x 600 600 x 600 600 x 600 600 x 600 600 x 600 600 x 600 600 x 600
Unload 300 x 300 300 x 300 300 x 300 300 x 300 300 x 300 300 x 300 300 x 300
Unloading with 170 x 170 170 x 170 170 x 170 170 x 170 170 x 170 170 x 170 170 x 170
suction plate (optional) (optional) (optional) (optional) (optional) (standard) (standard)
Max. speeds:
X axis m/min 120 180 180 180 120 120 120
Z axis 22 35 35 35 22 25 25
Y-axis, optional - 50 50 50 - - -
Drives Maintenance-free three-phase current servomotors
SheetMaster technical data Table 3-42
Suction cups The suction cups installed on the suction frame are important
elements of the SheetMaster and are available in three versions:
• Carrier suction cups suck-in using vacuum to transport the
sheet. Special carrier suction cups can also adopt special
tasks, e. g. to transport checker plate or non-magnetic sheets.
• Swivel cups allow sheets to be smoothly transferred with
punch or multi-purpose machine clamps.
• Peeler cups are used to separate the raw sheets.
Customized solutions It is possible to make individual modifications, according to client

needs, like magnetic suction cups and vacuum suction cups etc.

Suction cup assignment The suction cups are arranged according to most common DIN or
US sheet format. The standard layout can be found in the suction
cup layout plan.
Expanding magnet Expanding magnets are used to separate ferromagnetic sheets.

They are installed at the loading station.
Double sheet detector The SheetMaster is equipped as standard with a double sheet
detector for double sheet checking. A probe swivels towards the
underside of the sheet and checks whether two sheets are stuck
together by measuring the distance between two measuring points.
Upon discovery that two sheets are stuck together the peeler
suction cup bends the raw sheet upwards and the SheetMaster
moves up and down up to five times in order to reposition the lower
raw sheet.
Safe peeling (optional) The option safe peeling allows the safe peeling of raw sheets of up
to 4 mm sheet thickness (TruMatic 6000: 1.5 mm). This option is
recommended in particular for processing stainless steel,
aluminum and sheets with the following properties:
• Thin
• Film-coated
• Oily
Function After the double sheet detector has discovered that two sheets are
stuck together the stripper unit is then activated:
• The movement of the stripper unit creates a gap between the
two sheets.
• The air nozzle swivels down and blows compressed air pulses
into the gap. This peels off the lower sheet.
• The lower sheet is deposited on the loading station in its
correct position again.

Suction plate (Standard for

TruMatic 6000, otherwise
optional)
1 Workpiece 3 Suction frame

2 Suction plate
Suction plate with a typical part Fig. 13030
The suction plate, with its large amount of carrier suction cups as
well as the special suction cup arrangement on the remainder of
the suction frame, guarantees the safe and reliable withdrawal of
the following parts:
• Workpieces with a filigree form.
• Workpieces with a high risk of fracture.
• Narrow workpieces.
Sorting axis Y-400, only Via an NC-controlled axis the suction frame can be shifted by
TruPunch 5000 (Optional) 400 mm in the Y direction. The suction frame can thus be
positioned anywhere on this axis. This means finished workpieces
can be staggered cost efficiently. It is particularly useful to deposit
long, narrow parts ready-sorted in the Y direction.
Programming The SheetMaster is programmed using TruTops Punch.

Loading table (TruPunch 5000 only)
Preparation of the raw sheet For short sheet running times it is recommended to use the loading
during productive operation table.
1
2
3
1 Loading table 3 SheetMaster

2 Loading station 4 Unloading platform
Loading table TruPunch 5000 Fig. 47682
Function While the TruPunch 5000 processes a sheet, the SheetMaster

takes a new sheet from the unprocessed sheet stack. When this
happens, the double sheet check and the peeling process are
carried out. The SheetMaster positions the ready-aligned raw
sheet on the loading table equipped with suction cups. From there
is it is then only transferred to the TruPunch 5000 for processing.
Advantage The loading times are considerably shortened by using the loading
table.

GripMaster
The GripMaster automatically removes scrap skeletons and waste

strips from the machine and deposits them on the scissor table.
3
2
1 Scrap skeleton 3 Gripper bar

2 Scissor table 4 Cam
GripMaster with scissor table Fig. 26336
Function Additionally the two grippers (optionally 3 grippers) of the

GripMaster grasp the scrap skeleton. By moving the gripper bar on
the GripMaster and the machine table, the scrap skeleton is pulled
onto the scissor table. This is gradually stepped downwards as the
skeleton stack grows. The height of the skeleton stack is monitored
by light barriers in order to avoid collisions with the machine table.
The scrap skeletons can be conveniently unloaded with the help of
a tiltable pallet.

TruPunch TruMatic
3000 5000 3000 6000
Max. dimensions of mm 2500 x 2500 x 3000 x 4000 x 2500 x 2500 x 3000 x
raw sheets and 1250 1250 1500 1500 1250 1250 1500
processed
workpieces
Scrap skeleton mm 1400 x 1400 x 1400 x 1900 X1 1400 x 1400 x 1400 x
dimensions 1600 x 1600 x 1600 x 2100 X1 1600 x 1600 x 1600 x
LxBxH 1300 1300 1300 1800 1300 1300 1300
Stack height mm 300 400 400 400 300 300 300
Scissor table kg 5000 5000 5000 5000 5000 5000 5000
carrying capacity
Max. unloading kg 160 160 160 140 160 160 160
weight
GripMaster technical data Table 3-43
Removal of 3000 mm and The GripMaster is also available with a movable side extension
4000 mm scrap skeletons (optional) as an additional motion axis. If the side extension is
(optional) extended, scrap skeletons of up to 3000 mm can be removed. If
the side extension is in the other end position, the automated
waste grid removal is extended to 4000 mm.
No programming effort The GripMaster does not create any additional programming effort.

ShearMaster (not TruPunch 3000)
Breaking up scrap skeletons The ShearMaster breaks up the last sheet whilst the punch or
during downtime multi-purpose machine is already processing the next sheet. It is
mounted alternatively to the GripMaster.
2 3
1 Basic machine 3 ShearMaster

2 SheetMaster
Example: TruPunch 5000 with ShearMaster Fig. 47124
Function The ShearMaster transports the scrap skeleton on to the conveyor

table. The conveyor table can accept scrap skeletons in medium-,
large-, and maxi format and transports these in intervals to the
scissor unit. Four blades form the scissor unit and cut up the scrap
skeleton into handy pieces of a maximum size of 400 x 100 mm.
The cut up scraps are collected in a scrap container with a fill level
monitor and can be disposed of without too much expenditure.

ShearMaster for TruPunch 5000 and TruMatic 6000
Mild steel sheet mm 0.5 – 6.4
thickness
Stainless steel sheet 0.5 – 4
thickness
Aluminum sheet 0.5 – 6.4
thickness
Max. size of the scrap 400 x 100
pieces
Scissor width 1600
Working height of the • 1020
machine • 1120 (Recommended as a larger filling
volume of the scrap container and
connection to the scrap conveyer is
possible. For the TruMatic 6000 it is a
prerequisite).
Table 3-44
Scrap container
Maximum filling volume m³ 0.25
Maximum filling weight kg 350
Table 3-45
Large scrap container (on scrap conveyors)

Maximum filling volume m³ 1.2
Maximum filling weight kg 2000
Table 3-46
No programming effort The ShearMaster does not create any additional programming
effort.
Time-efficient interplay The SheetMaster and the GripMaster or ShearMaster process in a

time optimized way. The punch or multi-purpose machine can
continue processing as soon as the suction cups have taken the
finished workpiece, which is to be removed. In the same way, it is
not possible to remove the scrap skeleton with the GripMaster or
ShearMaster, while the SheetMaster suction cup is already
preparing the next raw sheet. The loading and unloading
procedures are fully automated and program-controlled, and are
executed without the intervention of the operator.

7.4 Flexible manufacturing cell
2
3
1 SheetMaster 5 SortMaster Pallet

2 Basic machine 6 SortMaster Box
3 ToolMaster 7 GripMaster or ShearMaster
4 Loading station
Example Fig. 47687
Loaded for everything The flexible manufacturing cell consists of the basic machine with
automation of the loading and unloading processes, an external
tool memory and automation components for sorting workpieces.
Components • SheetMaster for automatic loading and unloading.


• Loading station for taking up raw sheets.
• SortMaster Pallet, the sorting unit in Y direction for larger
workpieces.
• SortMaster Box, the sorting unit with four containers for small
workpieces.
• ToolMaster, tool memory with 40 or 70 tool stations.

TruMatic 6000)
Function The external tool memory ToolMaster extends the tool capacity of
the machine by an additional 40 or 70 tool stations and runs
without an operator.
1 2 3 4
1 Gripper 4 Rotary plate

2 Swivel arm 5 Console
3 Extension arm
Example: ToolMaster with 40 tool stations Fig. 47702

Structure The ToolMaster is firmly connected to the punch or multi-purpose
machine. The console carries the rotary plate with 40/70 tool
stations and the extension with the swivel arm. This has two
grippers to cushion the tools.
Function If a tool which is not in the machine's linear magazine is needed for
processing, it will by inserted by the ToolMaster. This usually
occurs before the machining of a sheet job begins.
If more tools are needed for a sheet job than are found in the linear
magazine, the replacing procedure from the ToolMaster takes
place during the machining.
Max. number of tools 40 or 70

Diameter of the rotary plate mm 1960
Speeds:
Rotational speed of the rotary table s/180° 1.5
Tool change time s 7.2–8.5
Table 3-47
Tool change Fig. 26338

Changing procedure • The machine's linear magazine moves the tool to be changed
into the change position.
• The rotary plate of the ToolMaster turns the desired tool into
the change position.
• The swivel arm is lowered, and the grippers on both ends grip
the tool in the linear magazine and the tool on the rotary plate
at the same time.
• The swivel arm moves upwards with both tools in the grippers,
turns by 180° and places the tools into the linear magazine and
onto the rotary plate.
• The swivel arm moves upwards into the initial position.
Setting-up during productive The set-up procedure of the ToolMaster takes place in productive
operation TruPunch 5000 and time. The machine can execute the sheet job without interruption.
TruMatic 6000 (optional) only The optional package contains a safety fence and a separate
safety light barrier.
Programming The ToolMaster is programmed using TruTops Punch.

Cart systems with travel rails
Function The cart system with travel rails offers a convenient alternative to a
loading station and/or an unloading platform. When using the
double cart, raw sheets are automatically prepared for the loading
of a machine equipped with the SheetMaster. The double cart
moves the sheets into such a position so that the SheetMaster can
take them up and feed them to the machine for machining.
1 SheetMaster 3 Raw sheets

2 Finished workpieces
Cart systems with travel rails Fig. 14012
Technical data
Max. weight per level kg 3000
Table 3-48

The sorted depositing of Ready cut parts and sheets can be sorted and deposited on a
finished parts double cart. The double cart can approach defined sorting
positions in Y direction, the SheetMaster takes over the positioning
in X direction.
Independent cart levels Both cart levels on the double cart can be positioned independently
of one another. A loading station can in comparison, however, be
loaded with twice the amount of raw sheets.
Loading and unloading The optional package contains a safety fence and a separate
during productive time safety light barrier. Loading or unloading during productive time is
(optional) also possible by positioning both cart levels independently from
one another. This is accomplished by one cart level moving out of
the safety range, whilst the other level moves into work position
underneath the SheetMaster.
Programming The double cart is programmed using TruTops Punch.
Variants • Loading: both levels are provided with expanding magnets and
loaded with raw sheets.
• Unloading: finished workpieces are deposited on both levels.
• Loading and unloading: Here two double carts are required for
this. One exclusively for loading and the other for unloading.
Advantages of a double cart • The rails of the double cart can be individually adjusted
with rails lengthways.
• Double cart rails can also be laid up to beyond the safety range
of the entire installation. Thus enabling manual loading and
unloading in productive time.
• Double cart rails can be both surface mounted and flush
mounted.

Cart system with toothed belt drive
The cart system with toothed belt drives is an inexpensive

alternative to the cart system with travel rails. Double carts with
toothed belt drives can approach any sorting positions in Y
direction, the SheetMaster takes over positioning in X direction.
1 2 3
1 Double loading cart 3 Double unloading cart

2 SheetMaster
Double cart with toothed belt drive Fig. 38817
Technical data
Max. weight per level (kg) 3000
Table 3-49
Guides instead of rails Double carts with toothed belt drives move along fixed guides,
which are installed directly on the ground. Adjustment and casting
as in case of cart systems with travel rails is not required.
Variants • Loading: both levels are provided with expanding magnets and
loaded with raw sheets.
• Unloading: finished workpieces are deposited on both levels.
• Loading and unloading: Here two double carts are required for
this. One exclusively for loading and the other for unloading.
Programming The double cart is programmed using TruTops Punch.

Characteristic features
Cart systems with Cart system with toothed

travel rails belt drive
Special sheet formats Yes Not planned
Bottom plate Yes Yes
Standard length in m 7.5 5 (Medium format)/

6.5 (Large format)
Individual rail lengths Yes No
Loading and unloading Yes Yes

during productive time
(optional)
Casting Yes (flush mounted) No
Laying of rails Surface mounted or Surface mounted

flush mounted
Table 3-50
Technical data Cart systems with travel rails Cart system with toothed belt drive
2
Medium format Large format Medium format Large format
Sheet format mm 2500 x 1250 3000 x 1500 2500 x 1250 3000 x 1500
Max. load capacity kg 3000 3000 3000 3000
Travel m 7 (standard) 7 (standard) 5 6.5
Max. operational m/min 18 18 18 18
Speed
Drive 3-phase motor 3-phase motor 3-phase motor 3-phase motor
Table 3-51
2
The cart system with travel rails also make it possible to use sheets in maxi
format.

SortMaster Box
Function The SortMaster Box is a sorting unit with four containers for die
take up of smaller workpieces. Controlled by a program, the
container intended for a particular purpose is rotated under the
support bracket of the punch or multi-purpose machine. As soon as
the part has been separated, it falls into the prepared container via
a fixed chute or the hinged parts chute.
1 Three-phase motor 3 Rotary table

2 Container
SortMaster Box Fig. 26339
Technical data TruPunch 3000 TruPunch 5000 TruMatic 3000 TruMatic 6000
Number of containers 4 4 4 4
Container inside mm 800 x 600 x 300 800 x 600 x 460 800 x 600 x 300 700 x 700 x 300
dimensions, B x D x H
Max. carrying capacity kg 500 500 500 400

per container
Max. part size mm 500 x 500 500 x 500 500 x 500 500 x 500
Table 3-52

Container removal The container can be removed from the front with an elevating cart
or a forklift after every 90° rotation.
Container removal in The optional package contains a safety fence and a separate
productive time (optional) safety light barrier. This means the containers can be removed in
productive time.
Box pallets Alternatively the containers can be replaced by box pallets.
Programming The SortMaster Box is programmed using TruTops Punch.
SortMaster Pallet
Function The SortMaster Pallet is a sorting unit for finished workpieces, on

(Euro)pallets in Y direction.
1 Chain strands
2 Pallet
SortMaster Pallet Fig. 47824
Function Europallets with workpiece can be arranged on the SortMaster

Pallet. The SheetMaster transports the finished workpieces
individually from the punch or multi-purpose machine to a program-
positioned pallet of the SortMaster Pallet.

Variants The SortMaster Pallet is available for:
• Four Europallets width or lengthways.
• Six Europallets width or lengthways.
Programming The SortMaster Pallet is programmed using TruTops Punch.
• In order to load and unload pallets with an elevating cart, the

pallets may be rotated by 90° and placed on the
SortMaster Pallet. Which is also useful for long, narrow parts
(Y).
Technical data TruPunch 3000 TruPunch 5000 TruMatic 3000 TruMatic 6000
Number of European 4 or 6 4 or 6 4 or 6 4 or 6
standard pallets
Pallet size, L x W x H mm 1200 x 800 x 140 1200 x 800 x 140 1200 x 800 x 140 1200 x 800 x 140
Stack height mm 200 200 200 200
Carrying capacity per kg 1000 1000 1000 1000
pallet
Traversing speed m/min 18 12 18 12
Table 3-53

7.5 Flexible manufacturing cell with
TRUMPF compact store
3
2
6
5
1 TRUMPF compact store (Single tower) 5 SortMaster Pallet

2 Basic machine 6 SheetMaster
3 ToolMaster 7 SortMaster Box
4 Storage cart 8 GripMaster or ShearMaster
Example Fig. 47825
The flexible manufacturing cell with its connection to storage

(Single- or double tower) consists of the basic machine with
automation of the loading and unloading processes in connection
with an additional tool memory, sorting units for finished
workpieces and a compact store.
Components • SheetMaster for automatic loading and unloading.

• Storage cart for the take up of raw sheets.

• SortMaster Pallet, the sorting unit in Y direction for larger
workpieces.
• SortMaster Box, the sorting unit with four containers for small
workpieces.
• ToolMaster, tool memory with 40 or 70 tool stations.
• TRUMPF compact store to increase the storage capacity for
automatic production.
Variants TRUMPF compact store is available in four variants:
Technical data Medium format Large format Maxi format Maxi format
Max. loading dimension mm 1250 x 2500 1500 x 3000 >1500 x 3000 >1500 x 3000
Max. loading weight per pallet kg 3000 3000 3000 5000
Table 3-54

7.6 Flexible sheet machining system
Example Fig. 47729
The large scale solution is a system unit consisting of several

manufacturing cells and other sheet metal working machines. The
central control point is the storage system. Here various formats,
loading heights and load capacities can be realized. Control and
monitoring functions are carried out by the TC CELL production
control system.

7.7 Control system and administration for
connection to storage
The current pallet layout is administrated and made visible by the

software for storage administration. It ensures, together with the
job table of the machine control system, the correct assignment of
job, NC program, raw material and pallet.
Depending on the size of the system, there are two different
software products:
CELL SERVER For production with up to four machines, up to five terminals and a
TRUMPF compact store (<200 storage positions):
• CELL-SERVER controls the material flow.
• All information about storage locations, pallets, and inventory
can be called up at any time.
• Each pallet has a permanent storage (fixed storage location).
TC CELL For production with several machines and a large storage, five
terminals and a warehouse (universal storage system or compact
store, >200 storage positions) and any amount of terminals. It
includes several modules:
• CELL BASIS: shared platform for all modules.
• CELL-STORAGE: control material flow and stocks, whereby
the storage positions can be used flexibly.
• CELL-MACHINE: connecting automatic material flow to the
machines. One module per machine.
• CELL-CONNECT: integrating external systems (e. g. PPS).

8. Control system technology
Open control system The TruPunch 5000 is equipped with a modern open control
system - the Siemens SINUMERIK 840D. The user interface has
been developed by TRUMPF and is based entirely on the
requirements of the operator.
New operation concept The operator should be able to enjoy working at the machine
without any stress, and should feel comfortable while doing so.
Operator prompting and design of the workplace were based on
these considerations.
The user interface is structured in a purely activity-oriented way,
regardless of the functional structure of the control system. Menu-
assisted functions which follow the operator's procedures are
provided for the desired action in each control area. The graphical
user interface corresponds to the Windows standard.
All the operating functions required for day-to-day operation can be
accessed directly. This allows the operating personnel to handle
production without long training or knowledge of the entire range of
functions of the control system.
The control system offers functions from other activity fields
wherever appropriate, without interrupting the sequence of
operation. It is no longer necessary to jump back and forth
between various "traditional" control operation modes.
Online help The integrated online help provides information and explanations
on the present topic at any time.
Ergonomics at the workstation The radiation-free TFT (thin film transistor) color display is the
control system's visual interface, and offers a picture that is sharp
and rich in contrast.
The operating keys have been grouped according to ergonomic
and functional aspects. A complete ASCII keyboard, which is
protected by a drawer, is used to enter the data.
Advanced The open control system enables a new diagnostics concept.

diagnostic options Malfunctions in the operational sequence are detected by the
sensor assembly and can be displayed on the screen after being
selected.
The error location is also displayed graphically if required. The
measures required to eliminate the error are described in plain text.
3-98 8BControl system technology B380EN03.DOC

1 Color display
2 Operating elements of the control system
3 Operating elements of the machine
Control panel Fig. 15355
Quick access to data The open control system provides new data transmission options.
The standard control system has a USB interface. Another data
transfer option is online data transfer via a network between the
programming system and the machine:
• Simple handling.
• Quick data transfer.
• Economical due to the application of Windows standard
network components.
• Access to different network drives from the machine.
Remote diagnostics Teleservice is one of our warranty services. During the warranty
period, the modem and software is placed at your disposal by
TRUMPF, free of charge.
B380EN03.DOC 8BControl system technology 3-99

9. Programming
9.1 Directly at the machine
The standard scope of delivery of the machine software includes

TruTops Punch Basic with the modules "Simple drawing" and
"Simple programming". These modules provide precisely the scope
of functions required for the programming of simple parts. Complex
parts are processed in TruTops Punch Basic.
TruTops Punch Basic and the "Simple drawing" module Fig. 48233en
3-100 9BProgramming B380EN03.DOC

9.2 In the office
TruTops Punch is the production system for the entire range of

sheet machining: Punching, nibbling, forming and combined laser
punching is possible with a single system.
User interface of TruTops Punch Fig. 51926en
The principle idea The aim of TruTops Punch is to generate NC programs for your
machine quickly, reliably and to a great extent automatically.
TruTops Punch; supports you all the way from drawing the
individual parts to data transfer of the completed NC program.
What does that mean? During each programming phase, TruTops Punch takes into
account:
• The specific options of your machine.
• The typical demands of sheet metal processing.
• The technology for punching, nibbling and laser machining.
At each individual programming step, the TruTops Punch has

already set its sights on the execution of the program on the
B380EN03.DOC 9BProgramming 3-101

machine. All functions which you program or which are created by
the system are checked on the basis of the technology and
corrected if necessary.
Basis: Database with rules Programming of machining is based on the information contained
in the database. The database provides everything needed to
program and generate the NC program.
Besides the NC components, the machine configuration is also
stored in the database. This allows an NC program tailored to the
machine to be generated.
Fast NC programs With TruTops Punch you can create NC programs quickly and
reliably.
The speeds of the machine axes are analyzed during optimization
in . The faster axis is favored by during the processing sequence.
Defining machining: What is done

automatically?
Punching • Contours are recognized automatically: TruTops Punch knows

how to distinguish between inner and outer contours. Punching
operations are automatically carried out on the correct side.
• Nibbling contours automatically: Entire contours consisting of
several geometric elements are machined automatically. This
applies to both inner and outer contours.
• Punching single holes automatically: TruTops Punch defines
the machining of single holes with standard tools (round,
rectangular, square, oblong hole) and special tools
automatically.
• Automatic pre-punching of piercing holes.
• Machining operations that you define yourself are checked
automatically. Examples: Monitoring of the permissible
punching force, warning of scraping cuts, inspection of damage
to contours, indication of collisions, inspection of violations of
dead areas.
3-102 9BProgramming B380EN03.DOC

10. The most important options
Advanced punching equipment Active die Marking/quick beading function

Die spray lubrication Engraving function
MultiTool function Deburring and roller technology
function
MultiShear function SoftPunch function
MultiBend function StripLine
Tapping function Adaptive stroke calibration
Advanced machine equipment Additional clamps Brush tables with loading and
unloading aid
Clamps to be opened individually Repositioning cylinders
Height-adjustable clamps TruTops Punch complete package
Sensor for parts chute TruTops Message
Vibration-proof installation
Automation options SheetMaster SortMaster box

Loading table SortMaster Pallet
GripMaster Cart systems with travel rails
ShearMaster Cart systems with toothed belt drive
ToolMaster
Machine accessories QuickMove QuickPad

QuickSet Tool adjustment aid
QuickLoad Whisper tools
QuickSharp
The most important options Table3-55
B380EN03.DOC 10BThe most important options 3-103

10.1 Active die
Fig. 54430
Non-scratch punching and The active die acts like a second punching head with a stroke from
forming below. This enables non-scratch machining because it moves
downward during the positioning of the sheet.
In addition, tools can also be used for more flexible forming.
Advantages • Non-scratch punching and formed area processing through

dynamic lowering of the die during sheet positioning.
• Larger and higher formings with special tools for the active die.
• Collision avoidance: the active die can be lowered for
downward formings.
• Material gain: Formings can be placed more closely to the
clamps because the part is always lying flat on the machine
tables.
• Quieter machining: the sheet is no longer raised during
machining.
• Simple programming: the active die presents no collision
contours.
3-104 10BThe most important options B380EN03.DOC

10.2 Die spray lubrication
1 Mixer jet
Fig. 53112
Lubricating sheets from A special mixer jet (1) and pressure generate a fine oil mist, which
below is sprayed systematically onto the underside of the sheet. The
sheet is moved into the spraying position for this purpose.
Recommended in particular for extrusions, formed areas and
tapping.
Advantages • Reduced friction between the lower tool and sheet.

• Considerably higher tool service life.
• Better forming quality.
• The time-consuming process of manually oiling the sheets is
no longer necessary.
• Oiling at specific points reduces oil consumption (minimum
amount lubrication) and is therefore environmentally friendly.

10.3 Brush tables with loading and
unloading aid
Fig. 53079
Avoiding scratches and The brushes prevent any direct contact between the underside of
reducing noise the sheet and machine components, in particular the die, which
might cause scratches.
The sheet slides on the brushes. This ensures that the marks on
the underside of the sheet caused by ball rollers from the table are
avoided.
The ball rollers positioned between the brushes (the loading and
unloading aid) make it easier to move the sheet on the base plate.
Advantages • The brush table is the correct solution particularly for thin
sheets.
− The loading and unloading aid in the form of ball rollers
allows sheets to the loaded and unloaded conveniently.
• Noise reduction.

10.4 Height-adjustable clamps
1 Height-adjustable clamps
Fig. 41801
Vertical movement 12 mm The height-adjustable clamps are mounted in such a way that they
can move in the Z direction. The possible stroke movement is
12 mm.
The stroke movements of the clamps have the following

advantages:
• Initial tension of the sheet in the area close to the clamps can
be reduced. As a result, the load pressure of the sheet on the
die is reduced. This makes it possible to avoid scratches on
the underside of the sheet to a large extent.
• This is particularly important for sheets with vulnerable
surfaces.
• Formed sections can be brought into the vicinity of the clamps.

Chapter 4
Operation
Part 1: Control elements ........................................................... 4-7
1. Control elements: Overview ......................................... 4-7
2. Control panel with color display.................................. 4-9

2.1 Operating elements of the machine .............................. 4-10
2.2 Operating elements of the control system..................... 4-14
3. Keyboard ...................................................................... 4-18
4. USB connection ........................................................... 4-19
Part 2: User interface............................................................... 4-20
1. Structure of the user interface ................................... 4-20

1.1 Menu bar........................................................................ 4-21
1.2 Status line ...................................................................... 4-21
1.3 Message bar .................................................................. 4-22
1.4 Softkey bar..................................................................... 4-22
1.5 Display area................................................................... 4-22
B380EN04.doc Operation 4-1

2. Machine submodes ..................................................... 4-23
2.1 AUTOMATIC submode.................................................. 4-23
2.2 MDA submode ............................................................... 4-24
2.3 JOG submode................................................................ 4-24
3. Control areas................................................................ 4-25
4. Diagnostics .................................................................. 4-26
5. PRODUCTION Operation ............................................ 4-27

5.1 PRODUCTION Single job.............................................. 4-27
Layout of graphics .................................................... 4-27
5.2 PRODUCTION Production plan .................................... 4-30
5.3 NC program management in the NCU .......................... 4-32
5.4 PRODUCING machine components ............................. 4-33
5.5 PRODUCTION Program options ................................... 4-34
5.6 PRODUCTION Switch elements ................................... 4-35
Operating the switch elements ................................. 4-35
Z axis calibration (optional) ...................................... 4-38
Switch elements H+L diagnostics page 1 ................ 4-39
SortMaster Box switch elements (optional).............. 4-40
SheetMaster axis switch elements (optional)........... 4-40
SheetMaster General switch elements (optional) .... 4-41
5.7 PRODUCTION: Tables.................................................. 4-42
Loading sheets ......................................................... 4-43
Sheet unloading........................................................ 4-46
Sheet technology...................................................... 4-54
Workpiece removal................................................... 4-55
Repositioning............................................................ 4-60
Tool technology – Punching/general ........................ 4-64
Tool technology – Quick beading (optional)............. 4-67
Tool technology – Multishear (optional) ................... 4-67
Tool technology – Roller tool (optional).................... 4-69
6. SETUP Operation......................................................... 4-72

6.1 SET-UP Switch elements .............................................. 4-72
4-2 Operation B380EN04.doc

Punching switch elements........................................ 4-73
SortMaster Box switch elements (optional).............. 4-74
Support table switch elements (optional) ................. 4-75
SheetMaster switch elements (optional) .................. 4-76
Stripper unit switch elements (optional) ................... 4-77
ToolMaster switch element (optional)....................... 4-77
Loading table switch elements (optional) ................. 4-78
6.2 SET UP Jog mode ......................................................... 4-79
6.3 MDA SET-UP................................................................. 4-80
7. PROGRAMMING Operation ........................................ 4-81

7.1 NC Editor ....................................................................... 4-81
7.2 PROGRAMMING NC program management................ 4-81
7.3 PROGRAMMING File management.............................. 4-83
7.4 Sending NC programs from the program manager....... 4-86
8. TOOLING Operation .................................................... 4-87

8.1 TOOLING Tool table (autom.) ....................................... 4-87
8.2 TOOLING Tool table (manual) ...................................... 4-87
Setting up rails.......................................................... 4-87
Setting up the ToolMaster (optional) ........................ 4-87
Set up rail/tool (optional)........................................... 4-89
8.3 Selecting NC programs ................................................. 4-90
8.4 TOOLING Rail allocation ............................................... 4-91
8.5 TOOLING tool allocation ............................................... 4-91
8.6 TOOLING Tools............................................................. 4-93
Required tools .......................................................... 4-93
Tool change list ........................................................ 4-93
General tool data ...................................................... 4-94
Tool master data/status data.................................... 4-95
8.7 Explanation of the tool data ........................................... 4-97
9. MAINTENANCE/START-UP Operation..................... 4-102

9.1 Maintenance/start-up Data backup ............................. 4-102
Changing the configuration for a partial backup..... 4-104
Starting a partial backup manually ......................... 4-104
Starting a complete backup.................................... 4-105
9.2 MAINTENANCE/START-UP Display........................... 4-105
10. DIAGNOSTICS Operation.......................................... 4-106

10.1 DIAGNOSTICS Fault diagnostics................................ 4-106
10.2 DIAGNOSTICS I/O diagnostics ................................... 4-107

10.3 DIAGNOSTICS Remote diagnostics ........................... 4-107
10.4 DIAGNOSTICS Display original position..................... 4-108
11. Integrated MDR Operation (optional) ...................... 4-109

11.1 MDR Message text ...................................................... 4-109
11.2 MDR Creating and modifying message texts .............. 4-110
11.3 MDR Displaying and editing machine data ................. 4-112
11.4 MDR Creating and changing interruptions .................. 4-114
11.5 MDR Evaluating machine data .................................... 4-115
11.6 MDR Displaying the times in list form.......................... 4-116
11.7 MDR Changing the time .............................................. 4-116
Part 3: Operating the machine.............................................. 4-117
1. Switching the machine on and off ........................... 4-118

1.1 Switching on the machine............................................ 4-118
1.2 Switching off the machine in the event of
malfunctions or emergencies....................................... 4-119
1.3 Switching off the machine............................................ 4-119
2. Executing a program ................................................. 4-120

2.1 Executing a program automatically ............................. 4-120
2.2 Executing a program with the softpunch (optional) ..... 4-121
2.3 Triggering a single stroke ............................................ 4-122
2.4 Changing the forming depth ........................................ 4-123
2.5 Program stop during execution.................................... 4-124
2.6 Stopping programs ...................................................... 4-124
2.7 Reentry into a program................................................ 4-125
3. Working with the production plan ........................... 4-127

3.1 Creating a production plan .......................................... 4-127
3.2 Executing a production plan ........................................ 4-128
3.3 Restarting the execution of the production plan after
a program interruption ................................................. 4-129
4. Moving the axes manually ........................................ 4-130
5. Releasing the drive brakes ....................................... 4-131

5.1 Releasing the X and Y axis drive brakes..................... 4-131
6. Manual execution of the lubrication cycle .............. 4-132
7. Diagnostic functions ................................................. 4-133

7.1 Fault diagnostics.......................................................... 4-133
7.2 Displaying machine inputs and outputs....................... 4-134
7.3 Remote diagnosis via pcANYWHERE ........................ 4-135

7.4 Querying the software version..................................... 4-136
8. Managing master files ............................................... 4-136

8.1 Uploading NC programs from the USB interface ........ 4-136
8.2 Uploading NC programs from the hard disk ................ 4-137
8.3 Output of NC programs via USB ainterface ................ 4-138
8.4 NC program output on the hard disk drive .................. 4-139
8.5 Program part output via USB interface........................ 4-140
8.6 Deleting NC programs from the program manager..... 4-141
9. NC program management......................................... 4-142

9.1 Displaying NC text ....................................................... 4-142
9.2 Editing NC text............................................................. 4-143
Searching for a block in the NC text....................... 4-143
Searching for a function in the NC text................... 4-144
Searching for and replacing a function
in the NC text .......................................................... 4-144
Inserting an additional line...................................... 4-146
Copying and inserting text passages ..................... 4-147
Deleting text passages ........................................... 4-148
10. Editing tables based on NC text............................... 4-148
11. TOOLING .................................................................... 4-150

11.1 Creating an automatic tool table and
loading the tool rail....................................................... 4-150
11.2 Manually loading/unloading tools ................................ 4-151
11.3 Loading a tool from the rail onto the
ToolMaster (optional)................................................... 4-152
11.3 Correcting clamp positions .......................................... 4-153
11.4 Removing an active tool .............................................. 4-154
11.5 Unloading all tools ....................................................... 4-154
12. Operating the integrated MDR.................................. 4-154

12.1 Creating a message text.............................................. 4-155
12.2 Assigning a message text............................................ 4-155
12.3 Splitting up an interruption period................................ 4-156
12.4 Evaluating machine data ............................................. 4-157
13. Adjusting the pressure foot pressure ..................... 4-158
14. If problems arise ........................................................ 4-159

14.1 Removing stripper from stripper adapter..................... 4-159
14.2 Removing the punch from the punching head............. 4-161
14.3 Removing the die from the die holder ......................... 4-164
14.4 Replacing the stripper segment................................... 4-165

15. Using ShearMaster (optional)................................... 4-166
15.1 Starting and stopping ShearMaster manually ............. 4-166
15.2 Change scrap container .............................................. 4-167
15.3 Use ShearMaster in stacking mode ............................ 4-167
15.4 Technical notes............................................................ 4-168
15.5 Correcting malfunctions............................................... 4-168
Release tilted scrap skeleton ................................. 4-168
Release tilted scrap from the chute........................ 4-169
16. Using height-adjustable clamps .............................. 4-170

16.1 Moving height-adjustable clamps ................................ 4-170
16.2 Utilizing height-adjustable clamps ............................... 4-171
16.3 Help if problem arises................................................. 4-171

Part 1: Control elements
1. Control elements: Overview
1 Main switch at the switch cabinet 3 FOOT SWITCH FOR 4 Acknowledge light barrier foot
2 EMERGENCY STOP WORKPIECE CLAMP switch
Fig. 55150

Operating element Prerequisites Explanation
MAIN None This switch is used to turn the power

SWITCH supply of the machine and the control
system on and off.
• SET-UP Operation, JOG machine The foot switch is used to open or close
submode: no active FEED HOLD, the workpiece clamp.
WORKPIECE no dead area is violated.
CLAMP
or
• PRODUCTION Operation, AUTO

machine submode: operator-guided
with program running, even with
inactive light barrier.
None The foot switch is used to activate the

light barrier.
ACKNOWLEDGE
LIGHT BARRIER
None Pressing the impact button stops all

movements of the machine.
EMERGENCY Immediate interruption of the entire
STOP power supply of the system (except for
24 V control system voltage).
The axes of the reference points are
lost. The home position must be re-
approached.
A program that is not finished must be
restarted.

2. Control panel with color display
1 2
7 8 9
4 5 6
N10
N20
1 2 3
0 ,
Esc
LASER
LASER
TEST
1 Color display 2 Operating elements of the control 3 Operating elements of the

system machine
Fig. 26949

2.1 Operating elements of the machine
1 MACHINE ON/OFF 5 ACKNOWLEDGE LIGHT 9 START PROGRAM

2 FEEDRATE POTENTIOMETER BARRIER 10 FEED HOLD key switch
3 ESTABLISH HOME POSITION 6 START 11 EMERGENCY STOP
4 JOG KEYS 7 FEED HOLD
8 RESET
Fig. 55151

Control system ready for operation This button is used to switch the
EMERGENCY STOP is not pending machine on or off.
Machine On/Off The hydraulic motor is switched on with
The light barriers must be active.
MACHINE ON. Test cycles for
monitoring the supply devices
(compressed air, axes, oil supply etc.)
are executed. Service readiness is
indicated by the lit up button.
MACHINE ON is canceled with:
• EMERGENCY STOP impact
button.
• Errors which trigger an
EMERGENCY STOP.
The button flashes in MACHINE OFF
mode.
The EMERGENCY STOP is not active In Jog mode (control system in set-up
No active FEED STOP operation) all NC axes can be moved in
JOG a (+) or (-) direction using the jog keys.
KEYS The rotational axes (C1 and C2) can
not be moved.
None The indicator lamp flashes if the light

barrier is interrupted.
ACKNOWLEDGE
LIGHT BARRIER
INDICATOR LAMP
None All machine movements are stopped by

actuating this button.
FEED HOLD All initiated cylinder movements are
continued until a defined end position is
reached.
The reference points are maintained.
FEED HOLD is canceled by actuating
the Start button.
No machine movements are possible
as long as FEED HOLD is active.
The button is lit up if FEED STOP is
active.

None RESET interrupts controlling and resets

the control system to the default
RESET condition.
All active error messages are deleted;
active programs are aborted and
ended.
The home position can be lost by a
RESET.
The reference points are maintained.
Machine ON The axes are referenced and the home

No active FEED STOP position of the machine is established
APPROACH by actuating this button.
HOME POSITION • The ram control system moves into
reference position.
• Reference points of the Z axis are
approached.
• The reference points of the X and
Y axes are established.
• The ram control moves to C axis
reference position.
• The reference points of the C axes
(rotational axes) are established.
The button lights up when the home
position is reached.
The button flashes if the home position
has not yet been approached.
This function is only performed if no
home position has yet been
approached.
FEED HOLD is active.
FEEDRATE POTENTIOMETER is
inactive.
Light barrier acknowledged This button is used to acknowledge

FEED HOLD.
START
The home position has been The selected NC program is started by

established. actuating this button.
START PROGRAM FEED HOLD is not active.
An NC program has been selected to
be run.
The tools are set up.

None The potentiometer can be used to

regulate the positioning speed of the
FEEDRATE X- and Y-axes between 4 % and 120 %.
POTENTIOMETER Not effective when referencing the
axes.
In manual mode: travel regulation of
4-15 m/min.
In automatic mode: travel regulation of
4-108 m/min. with simultaneous axis
movement.
Screen display of the respective
positioning speed in percent and m/min.
None Pressing the impact button stops all

movements of the machine.
EMERGENCY STOP Immediate interruption of the entire
power supply of the system (except for
24 V control system voltage).
The axes of the reference points are
lost. The home position must be re-
approached.
A program that is not finished must be
restarted.
None Turn the key switch to the right to shut

down all drives. After removing the key,
the machine is protected against
operation by a third party.
FEED
HOLD KEY
SWITCH

2.2 Operating elements of the control
system
1 2 3 4 5 6 7 8 9 10 11 12 13
7 8 9
4 5 6
N 10
N 20
1 2 3
0 ,
Esc
LASER
LASER
TEST
14 15 16 17 18 19 20
1 DIAGNOSTICS 8 NUMBER PAD 15 FOCUS MENU

2 MAINTENANCE/INITIAL START-UP 9 ESCAPE 16 EXIT WINDOWS
3 TOOLING 10 ENTER 17 HELP
4 PROGRAMMING 11 PAGE UP 18 FOCUS
5 SET-UP 12 FAST 19 CURSOR AND TOGGLE
6 PRODUCTION 13 PAGE DOWN 20 MAGNIFYING GLASS
7 BACKSPACE 14 SOFTKEYS
Fig. 27027

None The activity buttons are used to select

individual activity fields.
PRODUCTION In switch-on condition, the control
system is set to the PRODUCTION
control area.
SETUP The PRODUCTION and SET-UP
operations can never be simultaneously
N10 active. Either PRODUCTION or SET-
N20 PROGRAMMING UP is always selected.
In addition, either PROGRAMMING,
TOOLING or MAINTENANCE can be
TOOLING selected.
DIAGNOSTICS can be selected
regardless of the currently active control
MAINTENANCE/ areas.
INITIAL START-UP The buttons of the active control fields
are lit up.
DIAGNOSTICS
None The user interface of the control system

and the WINDOWS operating system
EXIT are exited automatically if the EXIT
WINDOWS WINDOWS button is actuated.
The cursor is within an input field. The cursor is moved one character to
the left each time the BACKSPACE key
BACKSPACE is pressed. The characters immediately
to the left of the cursor are
simultaneously deleted when doing so.
None The cursor appears in the selected

frame if the FOCUS button is actuated.
FOCUS You can select functions or enter data
there.
The FOCUS and cursor keys can be
used to move forwards within a
selected frame.

None Confirmation button

• When entering data.
ENTER
• On selecting a program from a
program list.
• When selecting an item from the
menu bar.
None The cursor moves to the menu bar at

the top edge of the screen if the
FOCUS MENU FOCUS MENU key is actuated. Select
a menu and confirm by pressing
ENTER.
The topic is spread over several screen The PAGE UP and PAGE DOWN keys
pages. can be used to scroll through the
PAGE UP/ There is a scroll bar on the right side of pages.
PAGE DOWN the screen.
None The screen displays the last selected

status of the menu bar if the FAST key
FAST is actuated.
The last four statuses are saved and
can be called up by actuating the FAST
key repeatedly.
Not currently assigned.
MAGNIFYING
GLASS/ZOOM
Focus is in a selection field. A selection field is opened on the

screen by actuating the TOGGLE key.
TOGGLE The cursor keys are used to select a
term from this selection field.
The selection field is closed again with
the same key.

The focus is on the screen. The cursor keys can be used to move
the cursor to the left, right or upwards or
CURSOR downwards on the screen.
keys The focus can be switched from
element to element within a data group.
None The functions of the eight softkeys,

which vary depending on the selected
SOFTKEY activity area, are displayed at the
bottom edge of the screen.

3. Keyboard
The keyboard is divided into typewriter keys and special keys.

All required ASCII characters are entered into the control system
using the keyboard. An overview of the assignment of the most
important special keys is listed below:
F1 F1 is used to call up the online operating guide.
F2-F9 These function keys are used for the softkey functions displayed at
the bottom of the screen. Press any one of these keys to execute
the related function on the screen.
F10 F10 is used to move the cursor to the menu bar; F10 corresponds
to the FOCUS MENU key on the control panel.
F11 F11 is used to open the topic blocks of the menu bar to make them
available for selection; F11 corresponds to the FOCUS key on the
control panel.
BACKSPACE The <BACKSPACE> key is used to move the cursor one space to
the left within an input field. The characters immediately to the left
of the cursor are simultaneously deleted when doing so.
Tab key The Tab key is used to switch between different display areas
within a frame (input fields, selection fields etc.). The tab key
corresponds to the FOCUS key on the control panel.
CAPS LOCK The <CAPS LOCK> key can be used to write exclusively in capital
letters. Pressing this key once makes it unnecessary to keep the
<SHIFT> key pressed. This function is cancelled by pressing the
key again.
ENTER The <ENTER> key is used to save or confirm data entries made
within input fields.

SHIFT There are two shift keys on the keyboard. If you press this key and
enter a letter at the same time, the upper case character appears.
If you use another key on the typewriter section instead of a letter

key, the character on the upper part of the key will appear.
INSERT Text passages previously marked and copied or cut out can be
inserted at any position using the INSERT key.
DELETE The DELETE key is used to delete text passages irrevocably.
HOME The cursor goes to the beginning of a text line by pressing the
HOME key.
END The cursor is moved to the end of a text line by pressing the END
key.
PAGE UP/PAGE DOWN You can scroll between several text pages by pressing the PAGE
UP or PAGE DOWN key.
CURSOR keys The cursor keys can be used to move the cursor to the left, right or
upwards or downwards on the screen.
NUM LOCK The numeric keypad on the right side of the keyboard is activated
by actuating the NUM LOCK key.
4. USB connection
If there is no direct connection between programming software and

machine, data transfer and storage can take place via USB
interface. The USB port is on the right side of the control panel.

Part 2: User interface
1. Structure of the user interface
1 Menu bar 3 Message line

2 Status line 4 Softkey bar
Fig. 55161

1.1 Menu bar
The available topic blocks from which individual topics can be

selected are displayed on the white menu bar. The menu bar is
accessed by actuating the FOCUS MENU key. The desired topic
can then be selected using the cursor keys. The choice must be
confirmed with the ENTER button.
1.2 Status line
The current settings of the machine and the control system are
indicated by symbols and abbreviations on the status bar directly
under the menu bar:
Malfunction JOG The machine is in JOG operating

mode (SETUP activity)
Reference available AUTO Machine is in AUTOMATIC operating
mode (PRODUCTION activity area)
Reference missing MDA Machine is in MDA operating mode
(Manual Data Automatic, SETUP
activity field)
RESET is carried out Cycle ON, control system performs a
cycle
Read-in block active Data processing is carried out; no
entries should be made by the
operator nor the screen changed
Feed block active

Read-in block and feed block active

1.3 Message bar
The black message line is divided into three fields and used to
display error messages and information.
Error message If an error occurs, the control or machine element (e.g. NC, PLC,
MMC) that caused the error is displayed in the first field of the
message line. The corresponding error number appears in the
second field. The third field contains a short description of the
error.
Note If only a note for the operator is to appear in the message line, the
first two fields are empty and the short message appears in the
third field.
1.4 Softkey bar
The softkeys are at the bottom edge of the screen. They are
assigned different functions, depending on the selected control
area.
1.5 Display area
The image area consists of one or more frames. Depending on the

operation area selected
• Input fields for operator inputs.

• Selection fields.
• Tables
are opened and current system statuses (e.g. axis positions, feed
etc.) are displayed.
The FOCUS and cursor keys can be used to select the individual
fields. The TOGGLE key can be used to open selection fields.

2. Machine submodes
The machine can be operated in three different operating modes:
• AUTOMATIC mode.
• MDA mode.
• JOG mode.
The three machine submodes must be clearly distinguished from

the five control areas of the control system:
• PRODUCTION Operation.
• SET-UP Operation.
• PROGRAMMING Operation.
• TOOLING Operation.
• MAINTENANCE/INITIAL START-UP Operation.
The machine operating modes cannot be selected directly by

pressing a key on the control system user interface. However the
five operation areas of the Control can be selected by pressing a
button. The machine can be in different machine operating modes
within these activity fields. The corresponding operation mode is
indicated by a symbol in the status bar, depending on the function
selected by the operator.
2.1 AUTOMATIC submode
Definition This mode is for the fully automatic execution of part programs.
The machine can only be operated in AUTOMATIC operating

mode in the PRODUCTION activity field. This machine operating
mode is indicated by the "AUTO" symbol on the status bar of the
user interface.
Prerequisites The machine does not switch over to AUTOMATIC mode until
certain basic requirements have been fulfilled:
• The reference points of the axes have been established.

• The light barriers have been are activated.
If an NC program is to be executed fully automatically, the tools

must be loaded and the NC program split up and saved in the
program manager of the control system. Programs are selected
and executed in the PRODUCTION activity field in AUTOMATIC
machine operating mode.

2.2 MDA submode
Definition You can create and run part programs block by block in MDA
operating mode (Manual Data Automatic). To do this, you can
specifically enter the required movements in the form of individual
NC program blocks using the control system keyboard. The
entered program blocks are executed after actuating the "Start"
softkey.
The machine can only be operated in the SETUP activity field in

MDA operating mode (can be selected at the menu bar). This
machine operating mode is indicated by the "MDA" symbol on the
status bar of the user interface.
Prerequisites The same basic prerequisites for AUTOMATIC mode must be

fulfilled for the MDA mode.
2.3 JOG submode
Definition JOG operation mode is provided to set up the machine and to

move ("jog") the NC axes.
The machine is therefore always in JOG mode if the prerequisites

for AUTO or MDA mode are not fulfilled. This means that the
machine can indicate that it is in JOG mode in all activity fields. In
JOG mode, it is possible to:
• Moving NC axes manually,

• Approaching positions accurately.

3. Control areas
The five control areas of the control system can be selected with
the five buttons at the right edge of the screen or via the menu bar
of the user interface. The operations can be divided into two
groups:
Group 1:
PRODUCTION
SET-UP
Only one of the higher-level operations PRODUCTION and

SETUP can be selected at a time. The control system is either in
the PRODUCTION or SET-UP control area. The active activity
field is indicated by the corresponding button lighting up on the
right-hand side next to the screen.
In addition, a lower-level operation can be selected from group 2.
DIAGNOSTICS can always be activated.
A maximum of three buttons can light up at the same time.
Group 2:
PROGRAMMING
N10
N20
TOOLING
MAINTENANCE/INITIAL START-UP
Analogous to the operations of group 1, only one of the

subordinate operations PROGRAMMING, TOOLING and
MAINTENANCE can be selected at a time. Either
PROGRAMMING or TOOLING or MAINTENANCE is active in
addition to a button from group 1.

4. Diagnostics
Diagnostics does not belong to the operation areas of the control

system. A separate menu tree is opened whenever
DIAGNOSTICS is selected at the user interface.
DIAGNOSTICS
DIAGNOSTICS can be selected in addition to any of the five

control areas at any time.

5. PRODUCTION Operation
5.1 PRODUCTION Single job
Layout of graphics
The "PRODUCTION - Single job" initial screen is displayed on the

screen of the control system after starting up the control system
and finishing the initialization phase. NC programs are selected
and executed fully automatically and interrupted NC programs are
resumed within this control area.
Machine axes • The names of all machine axes are listed one above the other
in the first column of the table.
• The current positions (actual positions) of these axes in the
machine coordinate system are displayed in the position
column to the right.
• The third column in the table shows the distance the axis still
has to go to reach the required programmed value:
Distance to go = required value - actual value
• The unit of measure with which the axis data is displayed is

specified in the fourth column.
• Feed values are displayed at the bottom of the screen. The
programmed feed value appears in the left-hand column. The
central field gives the actual feed value and the right-hand
column shows the setting of the feed potentiometer in %.

Program information Information about the currently selected NC program is shown on
the right side of the screen:
• Selected program: The program name of the currently

selected NC program is displayed here.
• Active program: The program name of the currently active
program part is displayed here. It may be the name of a
subroutine or the main program.
• NC blocks: The program blocks that are currently being
processed are displayed here.
• Program status: The status of the selected program is
displayed in this information field. Depending on the current
program status, actions can be triggered or procedures can be
blocked. Three different statuses can be displayed:
- Program status running is displayed if the part program
was started with START PROGRAM and is running.
Program status running is also displayed if a feed block or
read-in block has been issued, the feed rate correction is
set to 0 %, the axis monitoring system has been triggered
or the nominal position values have been specified for the
respective axes in the NC program.
- Program status aborted is displayed if a program has
been selected but not yet started or if a running program is
aborted with RESET.
- Program status stopped is displayed if the program is
stopped by NC Stop, NC Stop axes, NC Stop at block limits,
M00, M01 or Single block operation.

Program data The program data of the NC program currently selected is
displayed in tabular form. The names of the main program and the
first seven subroutines are displayed in the first line. The current
position of the machine in the NC program part (block number)
while the program is executed is always displayed in the second
line.
The required number of program runs indicates how many times
the program part has to be executed.
The actual number of program runs indicates how many times the
program part has already been run.
Active functions The NC and machine functions which are active during the
execution of a program are displayed here. Functions of the PLC
are issued in the list of active synchronous functions, while the list
of active G functions/NC instructions displays language commands
and NC functions.
Softkeys:
Actuate the Program selection softkey to select an NC program for

Program execution on the machine. The "NC program management in NC"
selection
menu appears on the screen. Using the cursor keys, select a
program from the overview list displayed. The Program selection
softkey must be pressed for confirmation.
Press the Re-entry softkey to resume executing an interrupted NC
Re-entry program at the point where it was stopped.
Press the Display selection softkey to display the current axis and
Selection program data on the left side of the screen during the current
display
production process. An overview of the production plan can also
be displayed.
Press the Production plan softkey to display the current production
Production plan.
plan
Starting TruTops Punch Basic.

TruTops

5.2 PRODUCTION Production plan
Exactly one NC program is allocated to each sheet job. A sheet job

consists of a defined number of program runs of an NC program. It
is thus determined in the production plan that NC programs are to
be run by a machine and in which sequence. Sheet jobs can only
be generated from programs that are in the NC archive.
The production plan is displayed on the screen if you actuate the

Production plan softkey in the "PRODUCTION - Single job" menu.
Job data • Sequence: Shows the sequence number of the sheet job. The
jobs are performed in the order of their sequence numbers.
• Status: Shows the status of the sheet job. The following status
options may be selected:
- Available: the sheet job is enabled for both production of
the Tooling list and for execution.
- paused: The sheet job is taken into account during the
creation of a Tooling list, but not during the execution of the
production plan.
- disabled: The sheet job is neither taken into account during
the execution of a production plan nor during the creation of
the Tooling list.
• Designation: when creating a sheet job, any character or
number sequence can be entered in the "Designation" field.
• Program name: The program name of the NC program on
which the sheet job is based is displayed here.
• Req.: displays the number of sheets to be machined.
• Act.: The number of sheets which have already been
machined is displayed here.
• Pallets:
- first pallet (supply pallet): The number of the pallet is
displayed on which the sheets to be machined lie.
- Second pallet (replacement supply pallet): The number
of the pallet is displayed on which further raw sheets lie.

Softkeys:
Press the Create sheet job softkey if you wish to add an NC

Create sheet program as a sheet job to the production plan. The "NC program
job
management in NC" menu appears on the screen. Using the
cursor keys, select a program from the overview list displayed. The
Create sheet job softkey must be pressed again for confirmation.
Actuate the Modify sheet job/info softkey if you wish to view or edit
Mod. sheet the data of a sheet job in the production plan.
job/info
Press the Delete sheet job softkey to delete a sheet job from the
Delete sheet production plan.
job
Actuate the Set status softkey to change the status of the selected
Set sheet job. Actuate the softkey repeatedly until the required status
status
is displayed in the production plan.
Actuate the Prepare production softkey to automatically create the
Prepare tool set-up list for the entire production plan. The "TOOLING -
production
Tooling list autom." menu appears on the screen.
Actuate the Nesting softkey if you wish to process the job data of
Nesting an entire nest. There must first be a nest loaded in the production
plan. A nest always consists of several single jobs and is already
created by the programming system.
Press the Start/Stop production softkey to start or stop the
Start/Stop execution of the production plan. All enabled sheet jobs are run on
production
the machine in the order as their sequence numbers.
Actuate the Stop after sheet job softkey to interrupt the execution
Stop after of the production plan as soon as the current job has been
sheet job
completely executed.

5.3 NC program management in the NCU
This menu appears if you

• Select a program to be run on the machine.
• Add a program to the production plan as a sheet job.
Softkeys:
Press the Find program softkey if you wish to search for a certain
Find program. You have to know the exact name of the program and
program
enter it in this input field.
Press the Select program softkey to select an NC program for
Select processing. Clamp positions and tools are checked and the
program
automatic tool table is generated.
Actuate the Create sheet job softkey to add the selected NC
Create sheet program to the production plan as a sheet job.
job
Press the Production plan softkey to display the current production

Production plan.
plan
Actuate the Program all/NCU softkey to switch between the two

Program display types. The program list contains either all existing NC
all/NCU
programs or after changeover, only those NC programs that have
already been transferred to the NC core.
Press the Program notes softkey if you wish to make notes on a
Program certain program.
notes
Actuate the Check program softkey to check whether all the tools
Check and table entries required to execute the program are available.
program

5.4 PRODUCING machine components
Automation components of the machine can be displayed and

suppressed in the "PRODUCTION - Machine components" menu.
It is necessary to hide a component if a mechanical defect
prevents it from working properly. As a result, NC programs which
contain automated loading or unloading cycles can still be
processed. Manual loading or unloading processes are generated
instead of automatic loading or unloading processes without the
machine coming to a standstill and without an error message being
issued. The suppressed component can still be operated via the
switch elements.
Softkeys:
Actuate the Hide softkey if you wish to disable a machine

Hide component for normal operation (e.g. in the event of mechanical
defects to a component).
Actuate the Show softkey if you wish to restore a previously
Show suppressed machine component to normal operation (e.g. after
successfully repairing a defective component).

5.5 PRODUCTION Program options
Program operations can be changed by means of the 'Program

options' if the machine is operated in AUTOMATIC or MDA
operating mode.
Parameters The following program options can be selected with the FOCUS
key, and activated or deactivated with the TOGGLE key:
• Skip block: Blocks in the NC text with a "/" in front of the block
number are ignored during the program sequence.
• Test feed rate: travel motions are carried out at a defined feed
rate. The test feed rate is used instead of the programmed
travel commands.
• Rapid mode correction: The correction switch for the feed
rate also affects the rapid feed rate.
• Programmed stop: The processing of the program is carried
out in the block in which M01 is programmed.
• Program test: The required value displayed in the axis table
"simulates" the travel motion.
• Block-by-block: Default setting. All NC blocks are processed
in sequence without interruption.
• Single block: Select this setting if you wish to stop the
program at the end of each NC block.
• Single block (functions): Select this setting if you wish to
stop the program after each machine function block.
• Show all blocks: All NC blocks of the program are shown in
the current block display.
• Show motion blocks: only the travel blocks of the program
are displayed in the current block display.

5.6 PRODUCTION Switch elements
Switch elements provide the operator the option of executing

machine functions by simply pressing a button, without having to
know the corresponding NC functions. Only those switch elements
can be actuated that are suitable for the respective operation
situation and are able to be carried out safely. As a result,
considerably fewer switch elements are available to the operator in
"AUTO" operating mode than in "JOG" operating mode.
Operating the switch elements
The status of the switch elements is indicated by symbols on the

user interface:
• Two buttons means that two specific switch status types are
available (normal case).
• If only a single button is displayed, this means that only one
status can be described specifically, for example "highest
position of cutting head" approached (specific value), "highest
position" not approached (no specific value).
• If more than two (maximum six) buttons are displayed, the
corresponding switch operation can be executed in stages.
Select the desired switch element with your mouse.
Green/white:
The switch status described with text is active.
Green/red:
This status is briefly displayed as the transition status when
switching the switch element.
If this status is retained, the switch element cannot be switched
successfully. Additionally, an alarm window opens that contains
conditions that are necessary for the successful switching of the
element.
White/green:
Switch over was successful. The switch status described in words
on the left is active.
The switch status described in words on the left is not active.

Green:
The switch status described in words on the left is active.
Red:
The specific switch status cannot be switched. In addition, an
alarm window is opened containing the conditions required to
successfully establish the switch status.
General switch elements
• Workpiece clamp: The clamps used to hold the sheet are

opened or closed.
• Chip flap: Actuate this switch element if you wish to empty the
chip console while the program is running. If actuated:
- A stroke block is generated.
- The chip vacuum system is switched off.
- The chip flap is opened.
- The "Chip flap is open" message is generated.
- FEED HOLD is generated.
If the switch element is pressed again:
- The chip flap is closed.
- The chip vacuum system is switched on.
- The "Actuate START button" message is generated.
Note
The chip vacuum system is only switched on again if no
TC_SUCTION_OFF (chip vacuum system OFF) is active and the
chip vacuum system has not been switched off using the "Chip
vacuum" switch element.
• Chip vacuum: Actuate this switch element if you wish to

switch off the chip vacuum system while the program is
running. If actuated:
- The operation is saved.

This status is maintained until the end of the program and is
automatically deleted by RESET or the end of the program. If
the switch element is actuated again before the end of the
program:
- A stroke block is triggered.
- The stroke block is canceled.
Note
This function is only appropriate for thin sheets. The machine can
be damaged by switching off the vacuum system within the thick
sheet range. The punching slugs must be vacuumed!
• Softpunch (option): Actuate this switch element if you wish to

activate or deactivate the soft punch function (punching with
noise reduction) while the program is running. Prerequisite for
using the softpunch function: the TC_SOFTPUNCH_ON
function must be programmed in the NC program.
• Tool lubrication: Press this switch element to disable tool

lubrication (TC_TOOL_LUBE_ON) programmed in the
NC program. To reactivate the programmed tool lubrication,
actuate the switch element again.
• Sheet height monitoring (Option): Actuate this switch

element if you wish to switch sheet height monitoring on or off
while the program is running. If sheet height monitoring is
switched on, a light barrier is activated which indicates
"damaged sheet" in the event of an interruption.
Sheet height monitoring is suppressed during the unloading
procedure on machines with GripMaster (Optional). Vibrations
during the unloading procedure could otherwise interrupt the
light barrier.
• Auto-shutdown (option): Actuate this switch element if you

wish to activate or deactivate automatic shutdown. If automatic
shutdown is active, the machine's ON/OFF button flashes with
increased frequency. The machine is automatically switched
off if:
- M02 or M30 (Program or job end) is active for longer than
5 minutes
- There is no axis motion 10 minutes long none.

• H+L speed: Press this switch element if you wish to correct
the speed of punching strokes downwards.
• Stroke speed from PTT: Press this switch element if you wish
to correct the stroke speeds in the PTT Tables downwards and
upwards.
Z axis calibration (optional)
The measuring program is usually called up at the start of the

program and before a forming procedure.
• Measurement-Calibration-Cycle
The following variants are available in this cycle:
- Automatic: The Program decides on its own whether a
measurement should be carried out. Previous
measurements, in terms of deviations, are analyzed for this
purpose.
- Measure + /Compensate: A measurement is made at
every activation and the value measured is passed on.
- Only Compensate: There is no measurement. The last
value measured, however, is still passed on.
- Switched off: There is no measurement and no calibration.
• Delay time: Interval that has elapsed between 2
measurements. The prerequisite is that constant measuring
results were detected during previous measurements.
• Delete data: All previously detected measurements are
deleted. New series of measurements are taken.
• Batch changes: A control measurement is forced.
Example
.
N90 TC_SHEET_CALIB ("WZ. No.", X Measuring cycle
pos., Y pos.)
N100 TC_TOOL_NO ("19060030") Tool selection
N110 TC_TOOL_CHANGE Tool change
.

Switch elements H+L diagnostics page 1
Version codes and the H+L alarm telegrams are displayed on page
1 of the diagnostics.
• HL status display: Actuate this switch element if you wish to

activate or deactivate the HL status display. The status data of
the last error is displayed on pages 1 to 4 in the event of an
error.
• H+L Lib version (PLC): The version number of the H+L Lib is
displayed here.
• H+L CPU version: The version number of the H+L CPU
software is displayed here.
• HL axis version: The version number of the HL axis software
is displayed here.
• Alarm tele. byte 0 - alarm tele. byte 5: The data bytes of the
H+L alarm telegrams are displayed here.
Page 2 of H+L diagnostics contains the binary signals of the H+L

control system.
The switching thresholds of the UDP/LDP sub-assembly from H+L

as well as the pressure sensor levels and the TRUMPF error
numbers in the event of an H+L alarm are displayed on page 3 of
H+L diagnostics.
The nominal position and actual position of the punching head as

well as the current position (central position of the H+L control) are
displayed on page 4 of H+L diagnostics. The first center position
reference is the center position calculated after switching on the
main switch.

SortMaster Box switch elements (optional)
• Jog mode, positive: Actuate this switch element if you wish to

rotate the SortMaster Box one container position further in
positive direction in relation to the container number. The
prerequisite is that the light barrier at the SortMaster is not
interrupted, and that part removal via the chutes is not active.
• Jog mode, negative: Actuate this switch element if you wish
to rotate the SortMaster Box one container position further in
negative direction in relation to the container number. The
prerequisite is that the light barrier at the SortMaster is not
interrupted, and that part removal via the chutes is not active.
• Ack. contain. chngd: Actuate this switch element after
replacing a full container with an empty one. The
SortMaster Box will then automatically continue turn back to
the container position selected last.
GripMaster switch elements (optional)
• Scissor table up/down: Actuate this switch element to move

the scissor table up (in the control range) or down (into pick-up
position). The prerequisite is that a sheet is not about to be
unloaded with GripMaster.
• Move SHT: Actuate this switch element to move the scissor
table in Y direction. This switch element can only be selected
for machines with a movable scissor table. The prerequisite is
that a sheet is not about to be unloaded with GripMaster.
SheetMaster axis switch elements (optional)
Descriptions of the SheetMaster axes (X and Z) and the

SortMaster Pallet axes are listed below one another in the left-
hand column of the table. The current position of these axes is
displayed in the position column.

• X axis: The X-position of SheetMaster is displayed.
• Y axis (optional): The Y-position of SheetMaster is displayed.
• Z axis: The Z-position of SheetMaster is displayed.
• Measured sheet thickness:
The absolute sheet thickness which has been calculated after
measuring with the sheet thickness gauge is displayed. The
display is updated after every measuring procedure.
• Current vacuum value:
The current low pressure in mbar exerted on the programmed
suction cups during the removal process.
• Low pressure vacuum error value:
The vacuum error value of the exerted low pressure is
displayed in mbar. The value displayed here is the value that
falls short of the acceptable limit value.
SheetMaster General switch elements

(optional)
• Sort L2 delivery pos: Actuate this switch element if you wish

to move the SortMaster Pallet one pallet position.
• Sensor suction plate (optional): Actuate this switch element
if you wish to activate or deactivate the sensor suction plate. It
makes sense to deactivate the sensor suction plate if none of
the suction plate sensors are on the part due to the part
geometry.
• Vacuum monitoring: This switch element has two statuses:
- Standard: Vacuum monitoring begins with movement
release for SheetMaster and movement of the Z axis by
20 mm in the +Z direction.
- Sharp: Vacuum monitoring begins immediately with
movement release for SheetMaster.
• Centering lever: Actuate this switch element to swing in or
swing back the centering lever.
• Approach alternative position: The SheetMaster moves out
of a possible collision range by a predefined X value by
actuating this switch element.

Softkeys:
Depending on the configuration stage of the machine, other switch

element groups for "quick" switchover procedures are made
available for selection on the softkey bar. Actuate the softkey with
the desired switch element group to change to the list of these
switch elements.
Actuate the Selection softkey (only available for automated

Selection machines) to access the selection field. The desired switch
element group can be selected there with the cursor keys and
confirmed with TOGGLE.
5.7 PRODUCTION: Tables
The concept of outsourcing technology data from the NC program

into tables that then merely need to be called up in the NC
program was further developed by TRUMPF during the design of
the user interface for the BOSCH PNC-P control system.
What has long been the practice for laser technology tables has
now also been implemented for the tool technology and sheet
handling. Apart from the advantage of paging out technology data,
thus making NC text shorter and easier to read, there is also a
great advantage when post-processing NC text. Processes are no
longer modified directly in the NC text (prone to errors) but rather
by modifying parameters in the respective tables. The individual
tables and their parameters are described below.

Loading sheets
Sheet loading tables are program-specific tables that are

transferred with the NC program from the programming station to
the control system and stored there. All parameters required for
loading the machine with sheets are stored in these tables.
When running an NC program on the machine, a table, the data of
which is accessed by the control system, is selected by means of a
defined table call. The table is called up in the NC program with
SHL for SHEET_LOAD and a serial number and must be put in
brackets with quotation marks ("SHL-1"). Subsequent changes to
parameters are made by editing the table entries.
Manual loading • LoadMaster:

1: Manual loading.
3: Loading with SheetMaster (optional).
• Loading position X (write-protected): The loading position in
X direction is displayed in mm. This value is entered absolutely
in relation to the center of the punching head and may not be
subsequently changed, since all following dimensions are
based on this loading dimension.
• Loading position Y: The loading position in Y direction is
displayed here in mm. This value is entered absolutely in
relation to the center of the punching head.
• Feed: The speed at which the machine axes approach the
loading position is displayed here in m/min.
• Stop pin:
1: Index pin 1 is activated.
2: Index pin 2 is activated.
• Insertion aid: The insertion aids are raisable supporting rollers
that are only available in combination with the optional brush
table. They make manual loading easier.
0: The supporting rollers are not active.
1: The supporting rollers are active and move upwards.

Loading with the • Offset stack pickup position: The X position of the vacuum
SheetMaster (optional) carriage when picking up a sheet from the loading stack is
stored as a default value in the applications. If a different value
is desired, it can be entered in mm as value in the "Offset stack
pick-up position" table parameter. The entered offset value is
always based on the coordinate reference point on the suction
frame.
• Double sheet detector:
0: The sheet measuring device is not active when raising the
sheet from the loading stack.
1: The sheet measuring device is active when raising the
sheet from the loading stack. The sheet measuring device
takes the sheet thickness value from the sheet technology
table. If the measured value exceeds the value from the
sheet technology table by more than 50 %, the control
system issues the message "Double sheet."
• Peeling:
0: The peeling cycle is not active when raising the sheet from
the loading stack.
1: The peeling cycle is active when raising the sheet from the
loading stack. A peeling height, a dwell time and a reduced
speed are applied in the machine parameters. The peeling
height is lower than the sheet thickness measuring
position.
• Alignment (optional):
0: Loading cycle without loading table (optional).
1: Preparatory loading on the loading table (optional).
• LIFT speed: The speed at which the LIFT executes the
loading operation is displayed in %.
100 % = 180 m/min for the X axis.
100 % = 35 m/min for the Z axis.
100 % = 50 m/min for the Y axis (optional).
• LIFT acceleration: A percentage for the acceleration of the
LIFT during the loading operation is displayed here. 100 %,
whereby the following maximum acceleration values should be
observed:
SM without sheet: 7 m/s² for X axis.
5 m/s² for Z axis.
3 m/s² for Y axis (optional).
SM with sheet: workpiece dimension-dependent acceleration
for all axes.
• Suction cup selection: The 72 suction cups are divided into
six groups and can be activated individually. To avoid
overlapping, each of the 12 suction cups per group has been
assigned a valence number. These valence numbers have
been selected in such a way that none of the 12 defined
valence numbers can be the outcome of adding two or more
numbers. Groups 4 to 6 are optional.

Suction cup numbers Valence
Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 numbers
(optional) (optional) (optional)
1 13 25 37 49 61 0001
2 14 26 38 50 62 0002
3 15 27 39 51 63 0004
4 16 28 40 52 64 0010
5 17 29 41 53 65 0020
6 18 30 42 54 66 0040
7 19 31 43 55 67 0100
8 20 32 44 56 68 0200
9 21 33 45 57 69 0400
10 22 34 46 58 70 1000
11 23 35 47 59 71 2000
12 24 36 48 60 72 4000
Example:
The suction cups 27, 31, 33 and 36 from suction cup group 3 are
to be activated:
Valence number for suction cup 27: 4

Suction cup group 3 (25-36): 4504
• Pivot cup: The suction cups 1, 2 and 3 can be selected as

pivot cups for the transfer of the sheet. The selected suction
cups are then subjected to vacuum. At least two pivot cups
must be activated when the sheet is transferred to the
machine, since otherwise the sheet could slip.
All three pivot cups should be activated for sheets of 2000 x
1000 mm or larger. The pivot cups must be additionally
activated within suction cup group 1. Suction cups 1, 2 and 3
are coded as pivot cups in the same way as the carrier cup
coding is performed.

Sheet unloading
Sheet unloading tables are program-specific tables that are

the control system and stored there. All parameters required to
unload scrap skeletons or blanks are stored in these tables.
SHU for SHEET UNLOAD and a serial number and must be put in
brackets with quotation marks ("SHU-1"). Subsequent changes to
Manual unloading • Unloading unit:

1: Manual unloading.
2: Unloading via the parts chute.
3: Unloading with the SheetMaster (optional).
4: Unloading with the GripMaster (optional).
• Unloading position X (write-protected): The unloading
position in X direction is displayed here in mm. This value is
entered as absolute value in relation to the center of the
punching head.
• Unloading position Y: The unloading position in Y direction is
displayed here in mm. This value is entered as absolute value
in relation to the center of the punching head.
• Feed: The speed at which the machine axes approach the
loading position is displayed here in m/min.
• Part ID: The number of the finished part which is currently
unloaded is displayed.
• Minimum surface: Enter the surface of the part to be
unloaded in this parameter.
Note
To make sure the acceleration can be adjusted, the "Acceleration
adjustment" parameter has to exhibit the value 1 in the
SHEET_TECH table.

• Insertion aid: The insertion aids are raisable supporting rollers
that are only available in combination with the optional brush
table. They make manual unloading easier.
0: The supporting rollers are not active.
1: The supporting rollers are active and move upwards.
• All clamps are opened:
0: Only the individually selected clamps or clamp groups are
opened during the unloading process, not all clamps.
1: All clamps are opened during the unloading process.
The value must be set by default to 1 since no function is
available yet for the selection of individual clamps/clamp
groups.
• Clamp 1...5/Clamp group 1...5:
0: Clamp/Clamp group is not opened during the unloading
process.
1: Clamp/clamp group is opened during the unloading
process.
The respective value entered is not evaluated by the control
system. The selection of individual clamps/clamp groups has
not yet been included in the function range.
• Deactivate clamp sensors:
0: Do not deactivate any sensors.
1: Deactivate one sensor (requires at least one sensor).
2: Deactivate all sensors (pull-out control becomes inactive).

Unloading via the parts • Push-out path Y: The part is pushed out in Y direction by the
chute displayed value before the clamps are opened.
• Push-out speed: The speed at which the part is pushed out is
displayed here in m/min.
• Parts sensing (optional):
0: The light barrier used to register the falling parts is not
active.
1: The light barrier is active.
The unloading procedure is delayed if the "parts monitoring"
option is not available.
• Air blast assist (optional):
Removal of small punched parts via the rigid chute:
compressed air is blown out of a nozzle attached to the
punching head to support the part removal process if air blast
assist is activated.
0: Air blast assist is not active.
1: Air blast assist is active.
• Number of part removals:

0: The parts chute remains open after removing a part.
1: The parts chute is closed after removing a part.
• Assume highest position:
0: The punching head moves into WORKING POSITION
after the last stroke.
1: The punching head moves into HIGHEST POSITION after
the last stroke.
• SortMaster deposit site:
1: The part is thrown into container 1.

'
• Outside geometry X: The value for the maximum dimension
of the part to be removed in X direction is displayed here in
mm.
• Outside geometry Y: The value for the maximum dimension
of the part to be removed in Y direction is displayed here in
mm.
• Offset X: This value indicates the distance between the
separation stroke and the center of the flap in X direction in
mm.
• Travel back along push path: The part must return along the
programmed push-out path in X and Y directions if the
workpiece movements are programmed incrementally after the
unloading procedure. This is not necessary with absolute
programming.
0: The part is not returned along the push-out path.
1: The part is returned along the push-out path.
• Push-out path X: The part is pushed out in X direction by the
displayed value before the clamps are opened.
• Part chute selection:
0: The control system automatically selects the appropriate
parts chute.
1: Selection of the large parts chute (500 x 500 mm)
2: Selection of the fixed chute for small parts.

Unloading with the • LIFT removal position: The X position of the suction carriage
SheetMaster (optional) when picking up the workpiece from the machine table must be
determined using the suction cup layout plans.
• Deposit site (pallet no.): A maximum of 16 pallets can be
defined as deposit places for parts. The assignment of
numbers to the pallets varies for each automated machine
depending on the configuration stage.
• Offset in X, offset in Y: A standard X and Y position are
defined for each deposit site (pallet no.). If workpieces are to
be stored at other pallet positions, the positions must be
entered as offset values in X and Y direction.
The offset in X is always entered in mm.
The offset entry in Y depends on the deposit site:
- Deposit site on SortMaster Pallet: entry in mm.
- Deposit place on double or storage cart: entry of Y
position 1-19.
The entered offset value is always based on the coordinate
reference point on the suction frame.
• Suction frame offset Y (optional): the suction frame offset Y
is suitable for sorting parts, e.g. on the unloading platform.
Value range: +20 to –380 mm.
• Sheet thickness when depositing: When depositing the
parts, the LIFT lowers the suction frame slowly onto the sheet
stack during the initial unloading and stores this Z value. The
"sheet thickness during depositing" and an applied safety
distance are added to the saved Z value during the next
unloading procedure. Any further lowering of the suction frame
onto the calculated sheet stack height is performed quickly.
Note
With formed sections, the "material thickness during depositing"
varies from the sheet thickness during the loading process and
must be programmed accordingly as a greater value.
• Suction cup selection: The suction cup selection has already

been described under "Loading sheets with the SheetMaster
(optional)".
• Stack Number: The stack is displayed upon which the parts
are to be set down.
• Offset in X: An offset value in mm is displayed by which every
second part is to be set down in the X direction.
• Offset in Y: An offset value in mm is displayed by which every
second part is to be set down in the Y direction. This
parameter applies with the SortMaster Pallet or the Y axis
(optional).

• LIFT speed: The speed at which the LIFT performs the
unloading procedure is displayed in %.
100 % = 180 m/min for the X axis.
100 % = 35 m/min for the Z axis.
100 % = 50 m/min for the Y axis (optional).
• LIFT acceleration: A percentage for the acceleration of the
LIFT during the unloading operation is displayed here. 100 %,
whereby the following acceleration values should be observed:
SM without sheet: 7 m/s² for X axis.
5 m/s² for Z axis.
3 m/s² for Y axis (optional).
SM with sheet: workpiece dimension-dependent acceleration
for all axes
• SORT speed: The speed at which the SortMaster is to move
during the unloading procedure is displayed in %.
• SORT acceleration: A percentage for the acceleration of the
SORT during the unloading procedure is displayed.
Note
SHEET_TECH table.
• Maximum surface: Enter the surface of the part to be

removed with the SheetMaster. It is used to automatically
calculate the acceleration of the SheetMaster.
unloaded is displayed.

Unloading cycles:
• Remove parts from clamps.

The workpiece must be positioned in front of the tool holder in
Y direction before the unloading cycle can begin.
1: The unloading cycle is activated:
- The suction carriage travels into the programmed removal
position.
- The suction frame is lowered onto the workpiece.
- The selected suction cups are evacuated.
- The clamps open automatically.
- The suction frame is raised to a height of 8 mm.
- The cross rail moves in +Y direction (release).
- The deposit site is established, while at the same time the
clamps are reclosed and the machine resumes operation.
- The suction frame moves into the uppermost position.
- The suction frame is lowered onto the unloading platform.
- The suction cups are ventilated.
- The suction carriage moves into waiting position.
• Deposit part:
1: The cycle is activated:
- The workpiece is dropped after reaching the deposit site.
The height from which the part is dropped depends on
which of the two table parameters "Drop part from top" or
"Drop from defined height" has been activated.
- If the table parameter "Part under machine table" is also
activated, the part is dropped under the machine table.
• Drop part from top:

In addition to the activation of the "Deposit part" cycle, one of
the two table parameters "Drop part from top" and "Drop from
defined height" must be set to 1.
0: The "Drop from defined height" parameter must be 1.
1: The part is dropped from the top position.
• Drop from defined height:

0: The "Drop part from top" table parameter must be 1.
1: The part is dropped from a defined height.
• Part under machine table:

0: The workpiece is deposited on the unloading platform.
1: The workpiece is dropped under the machine table.

Unloading with the The table parameters correspond to the general unloading data for
GripMaster (optional) manual unloading and have already been described there. If the
value 4 = TRUMAGRIP is selected for the "Unloading unit"
parameter, the scrap skeletons and residual strips are unloaded
with the GripMaster:
• The GripMaster moves with open grippers in X direction from

the stack position to the take-up position. The cam moves
simultaneously in +Y direction to the take-up position.
• The GripMaster's grippers are closed and the cam lowered.
• The clamps are opened automatically.
• The GripMaster moves in +X direction, the cam in -Y direction
to the dropping position.
• The machine moves in +Y direction after reaching the dropping
position.
• The grippers are opened and the gripper bar moves rearwards
in +X-direction to the stack position (release).

Sheet technology
Sheet technology table • Sheet thickness: The sheet thickness of the sheet to be
machined is displayed in mm.
• Sheet dimension in X: The dimension of the sheet in X
direction is displayed here in mm.
• Sheet dimension in Y: The dimension of the sheet in Y
direction is displayed here in mm.
• Sheet type:
0: Even sheet.
1: Uneven sheet.
2: Flanged sheet.
• Non-scratch machining (optional):
0: The sheet is not low-scratch machined.
1: The sheet is low-scratch machined (working position
raised by 1 mm).
• Material: This field is currently unassigned and is not
evaluated by the control system.
• Working between clamps:
0: There is no machining between the clamps in the active
part program.
1: Machining is performed between the clamps in the
selected part program. This is relevant if the clamps of the
machine are not to be set to the magazine positions
specified by the program.
• Rail position clamp 1 - clamp 6: The rail positions where the
clamps for the workpiece clamp have to be attached are
displayed here.
• Smallest sheet size, largest sheet size:
The two parameters show the clamping range of the sheet
during the entire execution of the NC program. Repositioning
procedures are taken into account for the entry.
Example:
Smallest sheet size: 5.
Largest sheet size: 11.
>> The sheet covers the rail positions 5 to 11 during the
execution of the entire NC program.
Acceleration adjustment:
0: The acceleration defined at the program start applies to
the entire program.
1: The acceleration is adapted to the new sheet weight at
each PART_UNLOAD.
• Material density: Enter the material density of the material
you wish to process.
Steel: approx. 7.8 kg/dm3.
Stainless steel: approx. 7.8 kg/dm3.
Aluminum: approx. 2.7 kg/dm3.

Workpiece removal
Workpiece removal tables are program-specific tables which are

the control system, where they are stored. All parameters required
for the removal of parts are stored in these tables.
PAU for PART_UNLOAD and a serial number and must be put in
brackets with quotation marks ("PAU-1"). Subsequent changes to
Manual removal • Unloading unit:

1: Manual unloading.
2: Unloading via the parts chute.
3: Unloading with the SheetMaster (optional).
• Push-out path X: The number of mm the part is pushed out in
X direction is displayed here.
• Push-out path Y: The number of mm the part is pushed out in
Y direction is displayed here. The part can also be "pulled out"
using the scrap skeleton if a negative value is entered.
• Push-out speed: The speed at which the part is pushed out is
displayed here in m/min.
• Return along push-out path:
0: The pushing path is not retraced after the pushing out of
the part.
1: The part is automatically returned along the push-out path
after it has been pushed out. The part must be returned
along the push-out path if positions are established
incrementally after the part removal process. This is not
necessary with absolute programming.
Note
SHEET_TECH table.

• Chip flap closed:
0: The chip flap is automatically opened during the part
removal process.
1: The automatic opening of the chip flap is suppressed
during the part removal process.
the last stroke.
removed is displayed.
Part removal via the parts • Minimum surface: Enter the surface of the part to be
chute unloaded in this parameter.
Note
SHEET_TECH table.

• Outside geometry X: The value for the maximum dimension
of the part to be removed in X direction is displayed here in
mm.
• Outside geometry Y: The value for the maximum dimension
of the part to be removed in Y direction is displayed here in
mm.
• Offset X: This value specifies the distance between the
separation stroke and the center of the flap in X direction in
mm.
• SortMaster deposit site:
• Parts sensing (optional):
0: The light barrier used to register the falling parts is not
active.
1: The light barrier is active.
The removal process is delayed if the "parts sensing" option is
not available.
• Air blast assist (optional):
Removal of small punched parts via the rigid chute: If air blast
assist is activated, compressed air is blown out of a nozzle
attached to the punching head to support the part removal
process.
0: Air blast assist is not active.
1: Air blast assist is active.
• Part chute selection:
0: The control system automatically selects the appropriate
parts chute.
1: Selection of the large parts chute (500 x 500 mm).
2: Selection of the fixed chute for small parts.
• Number of part removals:
0: The parts chute remains open after removing a part.
1: The parts chute is closed again after removing a part.
• Manual removal:
0: Manual removal not active.
1: Manual removal active.
the last stroke.
• Separate, then open:
0: The parts chute is tilted and the part is punched free.
1: The part is punched free and the parts chute is tilted.
• Push-out, then open:
0: Parts chute is unfolded, part is pushed out.
1: Part is pushed out, parts chute is unfolded.
removed is displayed.

Part removal with the The table parameters correspond to the sheet unloading data for
SheetMaster (optional) the SheetMaster and have already been described there. Only the
unloading cycles vary partially.
Unloading cycles:
• Remove part:
0: The unloading cycle is not activated. "Push out and
remove part" unloading cycle must be activated.
position.
- The suction frame is raised to a height of 34 mm.
- The deposit site is established (the machine carries on
working after leaving the collision range).
• Push part out and remove:

0: The unloading cycle is not activated. The "remove part"
unloading cycle must be activated.
- The part is pushed out by the amounts entered in the
"Push-out path X and Y" table parameters.
position.

- The suction frame is raised to a height of 86 mm
(uppermost position).
- The deposit site is established (the machine carries on
working after leaving the collision range).

• Separation stroke with vacuum:
0: The separation stroke is triggered before the suction frame
of the LIFT is lowered onto the workpiece and the suction
cups are evacuated.
1: The separation stroke is only triggered after the suction
frame has been lowered onto the workpiece and the
suction cups have been evacuated.
• Stack Number: The stack is displayed upon which the parts
are to be set down.
• Offset in X: An offset value in mm is displayed by which every
second part is to be set down in the X direction.
• Offset in Y: An offset value in mm is displayed by which every
second part is to be set down in the Y direction. This
parameter applies with the SortMaster Pallet or the Y axis
(optional).

Repositioning
Repositioning tables are program-specific tables which are

the control system and stored there. All parameters required for
the repositioning procedure are stored in these tables.
RPO for SHEET_REPOSIT and a serial number and must be put
in brackets with quotation marks ("RPO-1"). Subsequent changes
to parameters are made by editing the table entries.
Repositioning table • Travel in X: The travel of the X axis after opening the
workpiece clamp is displayed here. This value is displayed as
a positive or negative incremental value.
• Travel in Y: The travel of the Y axis after opening the
workpiece clamp is displayed here. The value is displayed
incrementally and must never be negative.
• Feed: The speed at which the repositioning procedure is
performed is displayed here.
• Repositioning type:
1: The sheet is clamped with the punching head during the
repositioning procedure.
2: The sheet is clamped with the repositioning cylinders
(optional).
3: The sheet is clamped with the repositioning cylinders
(optional) and the punching head.
• Deactivate clamp sensors:
0: Do not deactivate any sensors.
1: Deactivate one sensor (requires at least one sensor).
2: Deactivate all sensors (pull-out control becomes inactive).
• Activate offset:
0: The travel paths in X and Y are evaluated during program
creation.
1: The travel paths in X and Y are calculated during program
execution.
• Clamping position X: The X position at the beginning of the
repositioning procedure is displayed here.
• Clamping position Y: The Y position at the beginning of the
repositioning procedure is displayed here.

Tool technology – Tapping (optional)
Tool technology tables are program-specific tables which are

the control system, where they are stored.
All parameters required to machine the sheets with special tools
(tapping, forming, marking etc.) are stored in these tables. When
running an NC program on the machine, a table, the data of which
is accessed by the control system, is selected by means of a
defined table call.
• C axis RPM, tapping: The speed at which the C axis rotates

during tapping is displayed here in rpm. Default value: 60 per
minute.
• Lubrication container number: A lubricant container is
available at the TruPunch 5000; default value: 1.
• Number of lubrication impulses: Enter the number of
lubrication pulses that are to be triggered; default value: 1.
Where there is a positive table entry n, lubrication occurs n
times per thread. Every nth thread is lubricated if the table
contents are negative.
• Working position offset (UDP): If the working position
changes during the execution of a program, this change
(incremental value in mm) is entered as working position
offset. The working position is raised by entering a positive
value and lowered by entering a negative value. Value range:
+5 to
–5 mm.
• C axis rotation: An absolute value for the number of C axis
revolutions is entered here (value for the depth of the thread);
default value: 1 revolution.
• Stroke speed downwards: The speed of penetration for
plunging into the sheet can be reduced.
Prerequisite: The parameter "Stroke speed from PTT" must be
activated in Production – General switch elements.
• Stroke speed up: The reverse speed from the sheet can be
reduced.
• Suction unit on/off: Actuate this switch element if you wish to

program:
Note
Tool technology – Engraving (optional)
• Plunge position offset (LDP): With engraving tools, you can

change the engraving depth by changing the value for the
plunge position. The plunge depth of the tool in the sheet is
reduced by entering a positive value and increased by entering
a negative value.
value and lowered by entering a negative value.
• Feed: The marking speed is entered in m/min. Default value:
1.5 m/min.
• Tool lubrication: Actuate this switch element to suppress the
tool lubrication (TC_ TOOL_LUBE_ON). To reactivate the
programmed tool lubrication, actuate the switch element again.

Tool technology – Tapping (optional)
• Plunge position offset (LDP): When rotating/bending, you

can change the forming height by changing the value for the
a negative value. Value range: +5 to –5 mm.
value and lowered by entering a negative value. Value range:
+5 to
–5 mm.
• Retract path: The dimension by which the tool has to be
retracted from bending before the punching head reaches its
overtravel height is entered here.
• Punching with delay on/off:
0: Punching with delay has been deselected.
1: Punching with delay is active. A single stroke is triggered
with PUNCH_ON after reaching the programmed position
and a delay of 0.2 seconds.
lubrication (TC_TOOL_LUBE_ON). To reactivate the
• Stroke speed downwards: The stroke speed while plunging
into the sheet (downwards) can be reduced.
• Stroke speed up: The reverse speed from the sheet
(upwards) can be reduced.

Tool technology – Punching/general
• Tool type: Enter the TRUMPF tool type of the tool for which
you wish to enter the UDP or LDP offset values.
1 Circular 20 Engraving
2 Rectangle with corner 21 Multicut
radius
3 Square 22 Louver cut
4 Rectangle 23 Beading
5 Thread 24 Plunge
6 Milling 25 Lowering
7 Square with corner radius 26 Disconnecting
8 Oblong 27 Multishear
9 Special shape 28 Rotating/bending
10 Center punch 29 Roller cutting
11 Thermal (laser/plasma) 30 Roller pinching
13 Forming 31 Roller folding
15 Banana 32 Roller beading
16 Radius 33 Engraving
14 Coining 34 Roller knurling
17 Triangle 35 Calibrate
18 Slot (straight)
19 Quick beading

• Plunge position offset (LDP): You can change the plunge
depth of a punching tool with this parameter. The plunge
depth of the tool in the sheet is reduced by entering a positive
value and increased by entering a negative value.
• Presser foot force (optional): You can set the desired
presser foot force within the value range of 4350 N – 20320 N.
• Stripper rod pressure:
0: Stripper rod pressure not active.
1: Stripper rod pressure active (pressure set with hand wheel,
stripper rod pressure is reduced by turning it counter-
clockwise).
• Presser foot on/off:
0: Punching with passive presser foot. The presser foot is
about 0.6 to 1.6 mm above the top edge of the sheet.
1: Punching with active presser foot. The presser foot is on
the sheet during punching.
• Softpunch on/off (option): Actuate this switch element if you
wish to activate or deactivate the soft punch function (punching
with noise reduction) during the program sequence.
and a delay of 0.2 seconds.
• Suction unit on/off: Actuate this switch element if you wish to

program:

Note


Tool technology – Quick beading (optional)
• Plunge position offset (LDP): With beading tools, you can

change the forming height by changing the value for the
a negative value.
• Feed: The rapid beading speed is entered in m/min. Default
value: 1.5 m/min.
Tool technology – Multishear (optional)
• Plunge position offset 2 (LDP2): When separating cleanly,

you can change the shear position by changing the value for
plunge position 2. The plunge depth of the tool in the sheet is
a negative value.
• Working height offset 2 (UDP2): This function is not yet
available.
and a delay of 0.2.
• Suction unit on/off: Actuate this parameter if you wish to

This condition is maintained until the end of the program and is
the parameter is pressed again before the end of the program:
Note
• Tool lubrication: Actuate this parameter to disable the tool

• Feed rate per stroke: Actuate this parameter if you wish to
change the feed rate per stroke.

Tool technology – Roller tool (optional)
• Plunge position offset (LDP): You can change the plunge

depth with the roller tools by changing the value for the plunge
position. The plunge depth of the tool in the sheet is reduced
by entering a positive value and increased by entering a
negative value.
• Retract path: The dimension by which the tool has to be
retracted from bending before the punching head reaches its
overtravel height is entered here.
• Feed: Actuate this parameter if you would like to change the
feed rate in m/min.
• Suction unit on/off: Actuate this parameter if you wish to
This condition is maintained until the end of the program and is

the parameter is pressed again before the end of the program:
Note

Softkeys:
Actuate the Program name softkey to go to the "Prog. name"

Program selection field. Open the selection field with the TOGGLE key and
name
select the desired NC program.
Press the Table name softkey to go to the "Tab. name" selection
Tab. name field and select a table.
Actuate the Page softkey to go to the top-right selection field and

Page select one of the two displays (Information regarding the workpiece
or Method selection).
Actuate the Parameters softkey to go to the input fields and edit
Parameters the parameters there. Observe the Input range displayed at the
upper right whenever you enter data. Data input must be confirmed
with ENTER. The TOGGLE key is used to switch between the
input fields.
Press the Delete softkey to delete an existing table. The
Delete tco_default table cannot be deleted.
Actuate the NC Editor softkey to return to the selected NC text.

NC Editor This softkey is only active if the table was accessed from an NC
program.
Press the Copy softkey to save a table under a new name.
Copy
Actuate this softkey to scroll between data groups.

Page >

Tool technology – Engraving (optional)
• Plunge position offset (LDP): When engraving, you can

change the forming height by changing the value for the
a negative value.
• Feed: Actuate this parameter if you would like to change the
feed rate in m/min.

6. SETUP Operation
6.1 SET-UP Switch elements
Switch elements provide the operator the option of executing

machine functions by simply pressing a button, without having to
know the corresponding NC functions. Only those switch elements
can be actuated that are suitable for the respective operation
situation and are able to be carried out safely. As a result,
considerably fewer switch elements are available to the operator in
"AUTO" operating mode than in "JOG" operating mode.
General switch elements
• Workpiece clamp: The clamps used to hold the sheet are

opened or closed.
• Left stop pin: The left stop pin for sheet insertion is moved up
or down.
• Right stop pin: The right stop pin for sheet insertion is moved
up or down.
• Release brake X: The brake for the X-drive is released, the
axis can be moved manually (e.g. after collisions, if moving the
axes with the JOG keys is no longer possible).
• Lubricate pinion: The lubrication cycle for the lubrication of all
pinions (X, Y, Z and C drives) is triggered.
• Lubricate tapping tool: Three lubrication pulses are triggered
by actuating the switch element.
• Cartridge clamp: If this switch element is pressed, the
cartridge clamp is opened or closed.

Punching switch elements
• Punch chute: The parts chute is tilted or closed.

• Chip flap: The chip flap is opened or closed.
• Tool lubrication: 1 lubrication pulse is triggered.
• Highest position: The punching head moves to the highest
position.
• Tool-change height: The punching head moves to tool-
change height.
• Reference height: The punching head moves to reference
height.
• Single stroke on: The following machine operations are
triggered:
- The working position is established.
- Tool inspection.
- The single stroke is triggered.
• Defective tapping tool: Press this switch element if during
approach of the home position of the C axis, a C1-axis error is
caused by a defective tapping tool.
• Tool clamp: The tool clamp used to hold the tool in the tool
adapter of the punching head is opened or closed. On
machines with die clamping-piston monitoring (optional), the
tool clamp can only be opened if the C axis is set to 0°.
Version codes and the H+L alarm telegrams are displayed on page
1 of the diagnostics.
• HL status display: Actuate this switch element if you wish to

activate or deactivate the HL status display. The status data of
the last error is displayed on pages 1 to 4 in the event of an
error.
• H+L Lib version (PLC): The version number of the H+L Lib is
displayed here.
• H+L CPU version: The version number of the H+L CPU
software is displayed here.
• HL axis version: The version number of the HL axis software
is displayed here.
• Alarm tele. byte 0 - alarm tele. byte 5: The data bytes of the
H+L alarm telegrams are displayed here.

Page 2 of H+L diagnostics contains the binary signals of the H+L

control system.
The switching thresholds of the UDP/LDP sub-assembly from H+L

as well as the pressure sensor levels and the TRUMPF error
numbers in the event of an H+L alarm are displayed on page 3 of
H+L diagnostics.
The nominal position and actual position of the punching head as

well as the current position (central position of the H+L control) are
displayed on page 4 of H+L diagnostics. The first center position
reference is the center position calculated after switching on the
main switch.
SortMaster Box switch elements (optional)
• Jog mode, positive: Actuate this switch element if you wish to

rotate the SortMaster Box one container position further in
positive direction in relation to the container number. The
prerequisite for this is that the light barrier is not interrupted at
SortMaster.
• Jog mode, negative: Actuate this switch element if you wish
to rotate the SortMaster Box one container position further in
negative direction in relation to the container number. The
prerequisite for this is that the light barrier is not interrupted at
SortMaster.
• SortMaster jog mode: Press this switch element if you wish to
rotate SortMaster Box in any angle position.

GripMaster switch elements (optional)
• Scissor table up/down: Actuate this switch element to move

the scissor table up (in the control range) or down (into pick-up
position).
• Move SHT: Actuate this switch element to move the scissor
table in Y direction. This switch element can only be selected
for machines with a movable scissor table.
• GripMaster up/down: Actuate this switch element to move the
GripMaster into the upper or lower position. The GripMaster
can only then be moved if the machine's working range is at
least 4 m in X direction. Large-sized sheets can be machined
with assistance of the auxiliary tables if the GripMaster is in the
lower position. This switch element is tied to the retractable
optional GripMaster.
• Gripper bar: Actuate this switch element to move the gripper
bar from the rear to the front or from the front to the rear.
• Cam: Actuate this switch element to move the cam from the
stack position to the transfer position or vice versa.
• Gripper: Actuate this switch element to open or close the
grippers.
• Travel cylinder: Actuate this switch element to retract or
extend the travel cylinder.
• Bracket arm forwards/backwards: Actuate this switch
element to move the bracket arm to 3 m or 4 m machining.
This switch element is tied to the optional movable GripMaster.
• Arm fixing device: Actuate this switch element to lock the
bracket arm of the optional movable GripMaster in the 3 m or 4
m position.
Support table switch elements (optional)
• Support table: Actuate this switch element to move the

support table to the front or to the rear.
• Support table cam: Actuate this switch element to move out
the support table cam. The support table cam is moved out to
couple the support table with the machine table in Y direction.
This switch element is tied to the optional movable GripMaster.

SheetMaster switch elements (optional)
• Vacuum: Actuate this switch element to switch the ejector

nozzle on or off. The ejector nozzle can, however, only be
switched off if the suction cups are on a pallet or on the
machine table.
• Sheet thickness gauge.: Actuate this switch element to raise
or lower the sheet thickness gauge.
Prerequisites:
The suction frame is at the top.
The LIFT is outside the machine range.
• Sheet thickness gauge.: Actuate this switch element to swing
in or swing back the sheet thickness gauge.
Prerequisites:
The suction frame is at the top.
The LIFT is outside the machine range.
• Centering lever: Actuate this switch element to swing in or
swing back the centering lever.
• Clear sheet: If the LIFT has already carried out the
preparatory unloading and is in waiting position, the sheet can
be placed on the loading stack again by actuating the switch
element (e.g. if the normal program sequence has been
interrupted):
The LIFT moves into the X pick-up position of the loading stack
at the speed programmed last and lowers itself onto the
loading stack if this switch element is actuated. The vacuum is
switched off and the sheet is deposited. The suction frame
moves upwards.
Prerequisite:
The loading cycle is not yet active.
• Clean suction cup: Actuate this switch element to start the
purging cycle for the suction cups.
• Suction cup leak test: Actuate this switch element to start the
suction cup leak test.
• Servomotor brake: Actuate this switch element to release or
engage the brake of the servomotors.
• Sort L2 delivery pos: Actuate this switch element if you wish
to move the SortMaster Pallet one pallet position.
• Approach alt. posit.: The SheetMaster moves by a
predefined X value out of a possible collision range by
actuating this switch element.

Stripper unit switch elements (optional)
• Vacuum stripper unit: Actuate this switch element to switch

the vacuum of the stripper unit on or off.
• Tilt cylinder: Press this switch element to bend the suctioned
sheet or to suppress the bending.
• Lifting cylinder: Actuate this switch element to move the
stripper unit out of the clamp's collision range.
• Swivel blow nozzle: Press this switch element to retract or
fold back the blow nozzle.
• Blowing: Press this switch element if the retracted blow
nozzle should blow air or not.
ToolMaster switch element (optional)
• Gripper: Actuate this switch element to open or close the two

pneumatically-actuated grippers at the two ends of the swivel
arm. The grippers can be opened or closed only if the lifting
device is in the lower position.
• Swivel arm: Actuate this switch element to rotate the
pneumatically actuated swivel arm of the TRUMATOOL by
180°. The swivel arm can only be rotated when the lifting
device is in the upper position.
• Indexing: The swivel arm of the TRUMATOOL is indexed to
rule out unintentional swivel movements. A pneumatic cylinder
retracts the indexing piston and the status "not indexed" is
displayed if this switch element is actuated. The indexing
piston is pushed back in again and the "indexed" status is
displayed if the switch element is actuated again.
• Lifting device: Actuate this switch element to move the lifting
device into the upper or lower position with the swivel arm.
• Magazine wheel pos.: Actuate this switch element to rotate
the ToolMaster rotary plate one magazine station further.
• Tool axis brake: Actuate this switch element to release the
brake of the ToolMaster rotational axis.
• Remove tool: This switch element can only be actuated if the
"Request" status is displayed (e.g. after program interruption
during a tool change). The tools currently in the grippers are
returned to their old stations by actuating this switch element.

Softkeys:
Actuate the Selection softkey to go to the selection field. There the

Selection required switch element group can be selected using the cursor
keys and confirmed with TOGGLE.
Depending on the axis table displayed on the left-hand side of the

screen, other axis softkeys are displayed on the left half of the
softkey bar. Actuate the softkey for the NC axis you wish to move
manually. The softkey appears on a yellow background and the
selected NC axis (machine, SheetMaster or SortMaster axis) can
be moved with the jog keys.
Actuate the LIFT-Z Release softkey to start the release cycle for
LIFT-Z the Z axis of the TRUMALIFT if the Z axis was moved previously
Release
onto the E-STOP limit switch. You must then actuate the RESET
and START buttons before you can move the Z axis with the jog
keys.
Loading table switch elements (optional)
• Loading table feed: Actuate this parameter to move the

loading table.
• Load. table vacuum: Actuate this parameter to switch the
vacuum of the suction cups on and off.
• Blow off loading table: Actuate this parameter to switch the
blow-off of the suction cups on and off.

6.2 SET UP Jog mode
The machine operates in JOG operating mode if jog mode is

selected. In JOG mode, it is possible to:
• Moving NC axes manually.

• Approaching positions accurately.
Options • Operation mode

- Jog mode: The NC axis (yellow background) is selected by
pressing the corresponding softkey; it can be moved
manually using the JOG keys. The current actual positions
are displayed in the axis table.
- Reference point: This function cannot be activated.
• Travel characteristics:
- Continuous: Select the "Continuous" travel characteristic if
you wish to establish an approximate position in JOG mode.
- Incremental: Select the "Incremental" travel characteristic
to move to a very precise position in jog mode. You must
also define an increment. The increment indicates by how
many mm the selected axis is moved per keystroke (+/-).
-
Softkeys:
Actuate the softkey of the NC axis which you want to move

manually. After the selection is made, the softkey is highlighted in
yellow and the axis can be moved with the JOG keys.

6.3 MDA SET-UP
You can create and run part programs block by block in MDA
operating mode (Manual Data Automatic). To do this, you can
specifically enter the required movements in the form of individual
NC program blocks using the control system keyboard. The
entered program blocks are run on pressing the "Start" softkey.
Parameters • NC blocks: Enter the program blocks to be executed in

semiautomatic mode in the white field.
• Program status: The status of the selected program is

displayed in this information field. Depending on the current
program status, actions can be triggered or procedures can be
blocked. Three different statuses can be displayed:
- Program status running is displayed if the part program is

running after being started with the Program Start softkey.
Program status running is also displayed if a feed block or
read-in block has been issued, the feed rate correction is
set to 0 %, the axis monitoring system has been triggered
or the nominal position values have been specified for the
respective axes in the NC program.
- Program status aborted is displayed if a program has
been selected but not yet started or if a running program is
aborted with RESET.
- Program status stopped is displayed if the program is
stopped by NC Stop, NC Stop axes, NC Stop at block limits,
M00, M01 or Single block operation.

7. PROGRAMMING Operation
7.1 NC Editor
You can edit existing programs and create new NC programs in

the NC Editor. You must enter the text using the ASCII keyboard.
The softkeys are used to edit NC text together with the
programming guide that contains information on the functions and
how to program them.
Softkeys:
Actuate the Exit softkey to exit the NC Editor and return to the
Exit program overview. You can use the cursor keys to select a new
program from the overview in order to view it in the NC Editor.
Press the Save softkey to save changes to the NC text.
Save
Actuate the Cut out softkey to cut text passages out of the NC text.
Cut Mark these text passages first by pressing the SHIFT and
out
CURSOR keys simultaneously.
Actuate the Copy softkey to copy text passages from the NC text
Copy and insert them somewhere else. Mark these text passages first by
pressing the SHIFT and CURSOR keys simultaneously.
Actuate the Insert softkey to insert text passages you have copied
Insert or cut out at another position.
Actuate the Search/Replace softkey to search for a certain text

Search/ passage or function within the NC text and replace it with another
Replace
function, if necessary.
Actuate the Search/Replace Next softkey to search through the
Search/Repla entire NC text for a particular text passage or function in order to
ce Next
replace it, if necessary, with other functions or terms.
7.2 PROGRAMMING NC program

management
The "PROGRAMMING - NC program management" menu

provides an overview of all main programs that are stored on the
hard drive of the control system in split up form. If a main program
(MP) contains subroutines (SR), you can display them by selecting
the main program in question with the ENTER key.

For every part of the program, the status, the origin, the
creation/modification date and the size are displayed for you. The
graphics and the data of the set-up plan for the highlighted
program in question are displayed in a preview window. Only those
programs for which the graphic simulation was aborted are not
supported graphically.
To edit a program, select it with the CURSOR keys or the mouse
and then press the Editor softkey. The NC text is displayed in the
NC Editor where it can be edited with the softkeys.
Softkeys:
Press the Search/New MP softkey to search for a particular main

Search/New program. You have to know the exact name of the program and
MP
or:
Actuate the Find/New main program softkey to create a new main
program in the NC Editor.
Actuate the Subroutine direct/new softkey to create a new
Direct/New subroutine in the NC Editor. You must know the exact program
SR
name of the main program here and enter it in the input field. You
must give the subroutine a new name.
Actuate the Check program softkey to check whether all the tools
Check and table entries required to execute the program are available.
program
Press the Program overview softkey to switch to the overview of

Program main programs.
overview

Press the Program notes, softkey if you wish to make notes on a
notes
Press the Editor softkey to view or edit the NC text of the selected
Editor program in the NC Editor.
Actuate the Delete main program and subroutines softkey to delete

Delete a main program with all of its subroutines and table entries.
MP+SR
Actuate the Delete single program softkey to delete a program part

Delete single (main program or subroutine). The table entries are maintained.
program
7.3 PROGRAMMING File management
The "PROGRAMMING – File management" menu provides you

can with an overview of the data management on the hard drive
(C:\DH\ToPsmanu.dir) of the control system. Programs created by
the programming software and transferred to the machine control
system are stored in this directory as master files. All network
drives connected to the control system are also displayed.
In this menu you can:

• Subdivide master files for use on the machine.
• Import main programs and subroutines to the program
manager from external files.
• Issue programs as files from the program manager.
• Reorganize the program manager.

Softkeys:
Actuate the Find file softkey to search through a directory for a

Find specific file. You have to know the exact name of the program and
file
Actuate the Split master file softkey to start splitting up a master file
Split master from the programming system into main program, subroutines and
file
tables.
Actuate the Com.fil.spl. with select softkey to start splitting up a
Com.fil.spl. master file from the programming system into main program,
with select
subroutines and tables and transfer it as active program to the
control system.
Actuate the Output program softkey if you wish to store an NC
Output program from program management as a file or master file on the
program
hard drive.
Actuate the Copy file softkey to save a master file under a new file
Copy name. An input field is opened in which the entire path and the
file
new file name have to be entered by pressing this softkey.
Actuate the Continue softkey to access a menu level with further
Continue softkeys.
Actuate the Delete file softkey to delete a file from data

Delete management.
file

The following softkeys can be accessed by actuating Next:
Actuate the Main program from file softkey if you wish to transfer a
Main file file to the program manager as a main program.
from file
Application: Test programs that have been created manually on a
different computer.
Actuate the Subroutine from file softkey if you wish to transfer a file
Subroutine as a subroutine to the program manager. The corresponding main
from file
program must already exist however.
Application: Test programs that have been created manually on a
different computer.
Actuate the Reorganization softkey if you, for example, receive
Reorganization error messages from the database when setting up the tools.
Reorganization is triggered and the database is "repaired".
Actuate this softkey to return to the superordinate menu.
Cancel

7.4 Sending NC programs from the
program manager
You can use this menu to recreate a master file with all related
table information from the corresponding main programs and
subroutines. You can also copy individual program parts as file
onto the hard drive or a USB memory stick.
This menu appears if you Press the Output program softkey during
the "PROGRAMMING - File management" operation. The list of
programs is identical to the list displayed in the "PROGRAMMING
– NC program management" menu. Only the allocation of keys in
the softkey bar is different.
Softkeys:
program
Actuate the Generate master file softkey to merge related main
Generate programs, subroutines and tables in order to create a master file
master file
and store it on the hard drive.
Actuate the Copy file softkey to copy a part of a program (main
Copy program or subroutine) as a file onto the hard drive.
file
Press the Program overview softkey to switch to the overview of

Program main programs.
overview
Press the Program notes softkey if you wish to make notes on a

notes
Actuate the Delete main program and subroutines softkey to delete

Delete a main program with all of its subroutines and table entries.
MP+SR
Actuate the Delete single program softkey to delete a program part

Delete single (main program or subroutine). The table entries are maintained.
program

8. TOOLING Operation
8.1 TOOLING Tool table (autom.)
The right tools need to be loaded from the tool store onto the tool
rail in order to execute an NC program fully automatically. The tool
set-up list for the NC program to be executed can be generated by
pressing a button In the menu "TOOLING - Tooling list
(automatic)". The tools are displayed in the list with all identification
features, such as identity number, tool dimensions, tool station etc.
8.2 TOOLING Tool table (manual)
It is often necessary to load and unload tools manually when

executing NC programs semi-automatically or operating in test
mode. All tools stored in the tool manager are available for manual
tooling.
Setting up rails
The tool list is displayed in the top half of the screen together with
all necessary identification features. The tools which are to be
loaded manually onto the rail or unloaded from the rail are entered
in the tool set-up list in the bottom half of the screen.
Setting up the ToolMaster (optional)
The tool list is displayed in the top half of the screen together with
all necessary identification features. The tools which are to be
loaded manually onto the ToolMaster or unloaded from the
ToolMaster are entered in the tool set-up list in the bottom half of
the screen.

Softkeys:
Actuate the softkey Program direct to directly select an NC

Program program for the automatic creation of a tool set-up list. You have to
direct
know the exact name of the program and enter it in this input field.
Actuate the Sort tools softkey to sort the tools either according to
Sort the ID number, tool type or according to the tool location.
tools
Actuate the softkey Select program to select an NC program for

Select the automatic creation of a tool set-up list from the overview table.
program
Actuate the Modify tool data softkey to modify the tool data of the
Modify selected tool. Only the following values can be subsequently
tool data
changed: regrind length, whisper tool yes/no, presser foot type,
permissible sheet thickness, optimized forming position.
Actuate the Acknowledge all set-up operations softkey once you
Acknowl. all have executed all the tool set-up operations included in the tool
set-up oper.
set-up list. The allocation of tool stations is modified according to
the tool set-up list in the database. The tooling status of all tool set-
up operations is set to "OK" in the tool set-up list. The tooling set-
up is not deleted.
Actuate the Delete set-up list softkey once you have executed all
Delete the listed tool set-up procedures and acknowledged them. The tool
set-up list
set-up list is deleted.
Actuate the Change curr. tool softkey if you either want to
Change automatically remove the active tool from the tool adapter
curr. tool
or
have already removed the tool manually from the tool adapter and
want to send the "Punching head empty" signal to the control unit.
Actuate the Tooling position softkey if you want to move the tool
Tooling rail to the left or right in order to load the tools.
position
Actuate the Print set-up list softkey to print the displayed tool set-
Print up operations on paper. The for this is that a printer is connected
set-up list
and the corresponding printer driver is installed.

Set up rail/tool (optional)
In the "Set up rail/TOOL" menu it is possible to reload tools directly

from the rail onto the ToolMaster or vice versa:
For retooling, a tooling pair must first be formed. A tooling pair
always consists of a rail and a tool station of which the "contents"
are to be interchanged. Several tooling pairs result in a retooling
list, which is displayed in the lower left half of the screen. The Start
tool set-up softkey is used to start retooling all tooling pairs.
Softkeys:
Actuate the Create softkey to add a tooling pair to the retooling list.
Create The tooling pair must to be formed first by selecting a rail station
and tool station. Each selection must be confirmed with the
ENTER key.
Actuate the Delete softkey to delete a tooling pair from the
Delete retooling list.
Actuate the Unload rail softkey if you want to reload all tools from
Unload the tool rail onto the ToolMaster. A retooling list is automatically
rail
created for all tools which are on the rail by actuating the softkey.
Actuate the Start tool set-up softkey to start reloading all of the
Start tooling pairs displayed in the retooling list.
tool set-up

8.3 Selecting NC programs
In this menu you can create automatic tool set-up lists other than
during the normal execution of programs.
This menu appears if you actuate the Select program softkey in the
"TOOLING - Tooling list (automatic)" menu.
Softkeys:
program
Actuate the Create tool set-up list softkey if you wish to create the
Create automatic tool set-up list for the selected program.
set-up list
Actuate the Program all/NCU softkey to switch between the two

Program display types. The program list contains either all existing NC
all/NCU
programs or after changeover, only those NC programs that have
already been transferred to the NC core.

8.4 TOOLING Rail allocation
In the "TOOLING - Rail allocation" menu, the current tool rail

allocation of the machine is displayed, the clamps are loaded and
unloaded and rail positions can be disabled or enabled. The
standard allocation of the tool rail can also be defined. Tools must
be set up by creating manual or automatic tool set-up lists, which
cannot be performed within this menu.
If two or more tools with the same ID number are on the tool rail,
the tool manager selects the tool for machining which is allowed for
the sheet thickness used. If no tool is allowed for the sheet
thickness used, the first one in numerical order is selected.
8.5 TOOLING tool allocation
The current allocation of the TRUMATOOLS with tools is displayed

in the menu "TOOLING - Tool allocation". Tool stations can be
disabled or enabled. A standard allocation of the tools can also be
defined. Tools must be set up by creating manual or automatic tool
set-up lists, which cannot be performed within this menu.
Softkeys:
Press the Re-locate clamp softkey if you want to move a clamp

Re-locate from one rail station to another one.
clamp
Actuate the Load/Unload clamp softkey if you want to additionally

Load/Unload set up a clamp on the tool rail or unload a clamp from the rail.
clamp
Actuate the Modify tool data softkey to modify the tool data of the
Modify selected tool. Only the following values can be subsequently
tool data
changed: regrind length, whisper tool yes/no, presser foot type,
permissible sheet thickness, optimized forming position.

Actuate the Disable/Enable softkey if you wish to disable or enable
Disable/ tools or rail stations (tool stations) or if you wish to define a tool on
Enable
the rail (tool) as a standard tool. A dialog window is opened by
actuating the softkey and two further keys can be selected:
• Disable/Enable: Actuate this softkey if you wish to block a tool
on the rail (tool) from usage or lift this block. If you select an
unallocated rail station (tool station), it is disabled or enabled
when creating tool set-up lists. The softkey is highlighted in
yellow if a tool on the rail (tool) or an empty rail station (tool
station) is disabled.
• Standard tool: Actuate this softkey if you wish to define a tool
on the rail (tool) as standard tool or wish to cancel the standard
tool identification of a tool. Standard tools are ignored when
creating tool set-up lists (tooling block). The definition of a
standard rail allocation (standard tool allocation) is therefore
possible.
Actuate the Unload all tools softkey if you wish to completely
Unload remove the tool rail (tool).
all tools
Actuate the Change curr. tool softkey if you either want to

Change automatically remove the active tool from the tool adapter
curr. tool
or
have already removed the tool manually from the tool adapter and
want to send the "Punching head empty" signal to the control unit.
Actuate the Tooling position softkey if you want to move the tool
Tooling rail to the left or right in order to load the tools.
position
Actuate the Program technology softkey if you wish to display

Program information of the current NC program, such as clamp positions
technology
and sheet dimensions.

8.6 TOOLING Tools
Required tools
All tools required to execute an NC program are entered in the

required tools list. As a result, the operator is able to display all of
the tools and the number of different tools which have to be
available.
Tool change list
All tool changes made by the machine while executing an NC

program are entered in the tool change list. If a tool is installed
several times in the tool adapter, this tool also appears several
times in the tool change list. This list must be observed if more
tools are required to execute a program than the number of
available rail positions.

Softkeys:
Actuate the Program direct softkey to directly select an NC

Program program in order to generate the required tools list or tool change
direct
list. To do this, you need to know the exact name of the program
and enter it in the input field.
Actuate the Select program softkey to select an NC program in
Select order to generate the required tools list or the tool change list from
program
the overview list.
Actuate the Tool requirement softkey to display the required tools
Tool list.
requirement
Actuate the Tool change softkey to display the tool change list.
Tool
change
General tool data
The overview list in the "TOOLING - Tools - General tool data"

menu contains the identification features of all tools stored in the
tool manager in the control system. Starting from this list, you can
edit tool data, find particular tools or have the list sorted according
to various criteria for a better overview.
Softkeys:
Actuate the Process softkey to edit the data of a tool or to add a

Process new tool to the tool manager.
Actuate the Disable/Enable softkey if you wish to disable (status 1)

Disable/ or enable (status 0) a tool when creating tool set-up lists.
Enable
Actuate the Sort according to ID softkey to order the list of all tools
Sort according according to the ID number in ascending order.
to ID
Actuate the Sort acc. to location ID softkey to order the tool list
Sort acc. according to the station number in ascending order.
to location

Actuate the Sort accord. to type softkey to sort the tool list
Sort accord. according to the tool type (geometry of the tools).
to type
Actuate the Find softkey if you wish to search for a particular tool in
Find the tool list. All the displayed criteria can be used for the tool
search. Either precise descriptions can be entered in the input
fields or just a few initial letters or numbers in front of the
percentage character. The percentage character replaces all of the
following characters ("wild card"). A list of all tools beginning with
the entered characters is then displayed.
Example:
ID no.: 400 %
A list of all tools beginning with 400 is displayed:
400568211
400761534
400928735 etc.
Tool master data/status data
All identification features of an individual tool are displayed in the

"TOOLING - Tools - Master/Status data" menu. All data can be
edited in this mask. New tools can be saved in tool management
and old tools which are no longer required can be deleted along
with all of the corresponding data.
Softkeys:
Actuate the Create softkey to add a new tool to the tool manager of
Create the control system.
Actuate the Change softkey to save the edited tool data.

Change
Actuate the Delete softkey to delete a tool from the tool manager of
Delete the control system together with all of its corresponding data.

Actuate the Quick scan softkey to move quickly through the most
Quick important tool data (ID number, presser foot type, sheet thickness,
scan
regrind length).
Actuate the Read data softkey to call up the tool data belonging to
Read a tool ID number.
data
Press the Duplicate tools softkey to display tools with the same ID
Duplicate number but different Duplo numbers.
tools
Press the Other multitool punches softkey to check whether the

Other MT tool data of all punches of a multitool are stored in the tool
punches
manager of the control system.
Press the Back softkey to display the overview list of all tools.
Return

8.7 Explanation of the tool data
All tool and rail allocation parameters are explained in alphabetical

order in the following:
• Sheet thickness: The sheet thickness for which the tool is

allowed to be used is displayed here in mm.
• Dup.no. (Duplo number): The Duplo number is a sequence
number that is assigned if several punches are stored in the
tool manager with the same geometric dimensions and ID
number.
• Stripper penetration depth: The penetration depth
corresponds to the dimension by which the punch can
penetrate into the stripper without destroying it.
Note
− The value of the penetration depth can be determined
using QuickSet.
− On the basis of the entered value, the machine calculates
the "lower dead point" up to which punching can be
performed without damaging the stripper.
QuickSet is a tool setting device that performs several
functions:
− Quick and safe setting of tools (sizes I and II) for TRUMPF
punching and contour-nibbling machines (N/C) possible.
− The punch and alignment ring are aligned outside of the
machine and fixed. The die and the aligned punch are
then allocated to one another.
− Down times of the machine for refitting are reduced to a
minimum.
− Determine the total tool lengths of flat punches or shear
punches and send them to the tool data management.
− Determine regrind lengths for flat or shear punches.
− Determining the die thickness and the regrind amount.
− Determine the penetration depth of a punch into the
stripper and send it to the tool data management.
− Mount the alignment ring in a separate additional holder.
• Stroke types: The stroke types describe the sequences

between the punch and the active die possible for this tool
(optional). Several stroke types are permissible.
• Stroke rate: The number of strokes carried out by the tool are
displayed.
• Stroke limit: The number of strokes for this tool can be
entered. If these number of strokes are carried out
successfully, a message is displayed on the user interface.

• ID no.: The ID number of the punch is displayed here.
• Serial number: Sequence number which specifies the number
of different tools which have to be loaded in the selected NC
program.
• Dim. 1, Dim. 2: See tool dimensions.
• Die height: A die height of 30 mm is entered for all tools. If the
options of the active die (optional) are used, the die height
must be recorded separately (see Technical Information
"Active die").
• MT type/punch (multitool type/punch number): The
multitool type indicates the number of punches per tool. The
punch number defines the MultiTool punch used for machining.
1: Normal tool with one punch.
5: Multitool with 5 punches.
10: Multitool with 10 punches.
• PF type (presser foot type):
0: Tool without presser foot.
1: Self-stripping tool.
2: Presser foot with a diameter smaller than 80 mm.
3: Presser foot with a diameter larger than 80 mm.
• Options: Defines whether this tool needs a special
prerequisite. Previously only the active die could be defined as
the condition.
• Optimized forming position (s = 0):
Forming operations are performed in a raised working position.
The working position to be established for the installed forming
tool is defined by the "Optimized forming position (s = 0)"
parameter:
-1: Standard forming tool:
The machine is operated in the normal forming position.
The distance between the bottom edge of the sheet and
the ram ( = UDP position) is 55.7 mm.
36.7-48.7: Variable forming tool:
The working position of the forming tool at a sheet
thickness of 0 mm is displayed here in mm. The optimized
forming position is a tool-specific master parameter that is
only defined for variable forming tools. Only variable
forming tools which are suitable for working in this
optimized forming position can be used. Please take the
value for the optimized forming position of a tool from the
technical information supplied together with the tool.
The forming depth is changed in the tool technology table by
means of the "Plunge position offset (LDP)" parameter.

• Storage location: See tool location.
• Station No.: See the tool location.
• Status T (tooling status):
-: The tool has not yet been loaded on the rail or the tool
loading operation has not yet been acknowledged.
OK: The tool has already been loaded on the rail and the tool
loading operation acknowledged.
• Status ST (sheet thickness status):
-: The tool is not suitable for use since the thickness of the
sheet to be machined does not correspond to the sheet
thickness allowed for the tool.
OK: The tool is suitable for use.
• Status (rail/tool allocation status):
--: Unassigned
BE: Occupied
PR: Clamp
GE:Blocked
ST: Occupied with standard tool.
• Sts (tool status): The status of the tool is described by the
status display, with:
0: Tool OK.
1: Tool disabled.
7: Faulty tool (tool must be recreated in the manager).
8: MultiTool data incomplete (some multitool punch
parameters have not been generated).
9: ID for tools that have been recreated in the tool manager
by the programming system.
• Punch No.: See MT type/punch.
• Toler. +/-: Each tool is assigned a defined sheet thickness that
it is able to machine. The tool may only be used for other sheet
thicknesses within a particular range. The tolerance +/-
specifies how much thicker or thinner than the defined sheet
thickness the sheet is allowed to be.
• WT (whisper tool):
0: No angle-sheared tool.
1: Angle-sheared tool.

• Tool length:
The tool length is measured from the top edge of the alignment
ring to the bottom edge of the punch.
34.3: new, short flat punch.

37.3: new, shear punch.
37.8: new, long flat punch.
Smaller value:
The tool was reground by the amount displayed in mm.
Note
• The setting of the tools is performed with the adjustment
device.
• The forming depth is not changed using the tool length, but
instead using the parameter "Plunge position offset (LDP)" in
the tool technology table!
• Tool dimensions: The geometric dimensions of the punch are

displayed here in mm.
• Tool location: A tool that has been created in the tool
management is either in the tool store or on the tool rail:
L: The tool is in the store.
S: The tool is on the rail.
• Tool station: A tool which has been stored in the tool

manager is either in the tool store or at a numbered position on
the tool rail. The arrow between the two tool stations indicates
the tooling direction:
->: The tool must be unloaded.
<-: The tool must be loaded.
--: The sheet thickness status of the tool is not OK. You must
insert another die before the tool can be set up.
The specified station numbers must be observed during the
tool loading operation.
• Tool type: The geometry of the punch is described by the tool
type: List of all TRUMPF tool types:

1 Circular 20 Engraving
2 Rectangle with corner radius 21 Multicut
3 Square 22 Louver cut
4 Rectangle 23 Beading
5 Thread 24 Plunge
6 Milling 25 Lowering
7 Square with corner radius 26 Disconnecting
8 Oblong 27 Multishear
9 Special shape 28 Rotating/bending
10 Center punch 29 Roller cutting
11 Thermal (laser/plasma) 30 Roller pinching
13 Forming 31 Roller folding
14 Coining 32 Roller beading
15 Banana 33 Engraving
16 Radius 34 Roller knurling
17 Triangle 35 Calibrate
18 Slot (straight)
19 Quick beading
• Item no.: Sequence number that indicates the number of tool

changes performed by the machine while executing the
selected NC program. If a tool is changed several times, this
tool also appears several times in the tool change list.

9. MAINTENANCE/START-UP Operation
9.1 Maintenance/start-up
Data backup
The machine and customer data that is stored on the hard disk of
the user interface, such as laser technology tables, customized
databases, part programs etc., can be partially or fully backed up
and restored by TRUMPF service technicians whenever
necessary.
The following functions can be called up via the "Data backup"

screen:
• Manual or automatic partial backup of the directories and files
defined in the control system: The number of partial backup
copies that can be simultaneously stored in a backup directory
can be configured as required. A maximum of 20 partial
backup copies can be stored. If the number of partial backup
copies defined in the configuration is exceeded, the backup
copies with the oldest date in the backup directory are
deleted.
• Partial backup procedures can be started manually at any
time.
• An automatic partial backup copy is made automatically
according to the selected interval after switching on the
machine (while the control system is started up).
• Complete backup of the entire hard disk on an additional hard
disk: All the data of the last complete backup copy is
overwritten each time a new complete backup copy is made.
• Partial or complete backup of the saved data by a TRUMPF
service technician: The restoration of data (even customized
data) is password protected and can only be performed by
TRUMPF service technicians. The current data on the hard
disk of the user interface is overwritten whenever data is
restored!

Note
No complete backup can be performed if no additional hard disk is
available. In this case this part of the screen and the Complete
backup softkey are grayed.
Softkeys:
Press the Change configuration softkey to select the
Change configuration for a partial backup:
configuration
• Backup path: Local hard disk, network drive or data storage
medium.
• Maximum number of backup copies that can be stored in
the selected backup directory at the same time.
• Time interval for automatic backups: "Daily", "Monthly",
"Weekly" or "Never".
Press the Partial backup softkey if data from a partial backup is to
Partial be restored to the hard disk. This function is password-protected.
backup
Press the Complete backup softkey if all data from a complete

Complete backup is to be restored to the hard disk. This function is
backup password-protected.
Press the Start backup softkey to start a partial or complete
Start backup backup procedure.

Changing the configuration for a partial
backup
1. Select Operation >Maintenance/Start-Up >Data backup.
2. Press Change configuration.

Change
configuration
3. Select the backup path.
Note
The backup path cannot be freely selected if the data is to be
backed up on the local hard disk. In this case the backup
path is defined in the control system.
4. To select the maximum number of backup copies to be

stored in the backup directory, press the Quantity + or
Quantity - softkey.
If the data is to be backed up automatically:
5. Select "Time interval".
6. Press OK.
OK
The configuration is saved.
Starting a partial backup manually
Prerequisite
The machining program is not active.

2. Press Start backup.
Start backup
3. Press Partial backup.

Partial
backup
The PC of the user interface is shut down. The partial backup is

stored when the control system is restarted.

Starting a complete backup
Prerequisite
The PC of the user interface has two hard disks.
The machining program is not active.

2. Press Start backup.
Start backup
3. Press Complete backup.

Complete
backup
The PC of the user interface is shut down. The complete backup is

stored when the control system is restarted.
9.2 MAINTENANCE/START-UP Display
The desired language and measurement system (metric/inches)

can be selected in the Display menu.
Softkeys:
Actuate the Apply language softkey to adopt the language selected

Apply with the cursor.
language
Actuate the Change meas. sys. softkey to switch between metric

Change and inches.
meas. sys.
Actuate the Softkey Tables menu in order to switch back and forth
Tables between Structure without submenus and Structure with submenus.
menu

10. DIAGNOSTICS Operation
10.1 DIAGNOSTICS Fault diagnostics
A list of active errors and messages generated when working at

the machine is displayed in the fault diagnostics. Furthermore, the
softkeys can be used not only to query the error text, but also the
cause, effects, location and measures to be taken to eliminate the
error.
Softkeys:
Actuate the All softkey to display a list of all errors and messages.
All
Actuate the Error softkey to display a list of all errors.

Error
Actuate the Messages softkey to display a list of all messages.

Messages
Actuate the Cause softkey to display the cause of the error and the
Cause measures to be taken to eliminate it.
Actuate the Error location softkey to display the error location, the
Error location effects and any comments.
Actuate the End softkey to go to the last line of the displayed list.
End
Press the Find softkey to search for a certain error number.

Find

10.2 DIAGNOSTICS I/O diagnostics
All digital inputs and outputs of the basic machine appear on the
screen display. The bits of the inputs and outputs and their
respective status are displayed in the table. The assignment to the
designations of the inputs and outputs in the right column is
approached via the column that is on a yellow background.
Softkeys:
Press the << >> softkey to switch between the individual inputs
<< >> and outputs.
Press the Selection softkey to display the selection list (basic

Selection machine...).
10.3 DIAGNOSTICS Remote diagnostics
By activating the remote diagnostics at the control system, it is

possible for a TRUMPF engineer to operate the control system on
the telephone and, in this way, locate and possibly solve any
problems. The remote diagnostics must be activated on the control
system on site.
Softkeys:
Press the Start softkey if you wish to start the remote diagnostics.
Start
Actuate the Menu softkey to receive written messages from

Menu TRUMPF (remote PC) or send written messages to TRUMPF (host
PC) via "Dialog".
Actuate the Quit softkey if you wish to quit remote diagnostics, i.e.
Exit to interrupt the telephone connection.

10.4 DIAGNOSTICS Display original
position
Whether the active system components are at home position or not

is displayed in this menu. The yellow and black home position
symbol appears next to the respective system component if it is at
home position.

11. Integrated MDR Operation (optional)
11.1 MDR Message text
The "Integrated MDR" (Machine Data Register) software program

automatically records all of your machine's operating times and
down times. The integrated MDR uses the two messages
"Machine running" and "Machine not running". The data is stored in
a database in chronological order and can be retrieved from there
and evaluated.
This allows a precise and rapid overview of the interruptions to the
machine run time.
Each interruption should also be assigned a reason however, in

order to be able to analyze the machine operations precisely.
MDR message texts are information on precisely these reasons.
They are first entered by the operator in a so-called "Message
tree" and can then be allocated to the interruption via the functions
of the integrated MDR.
The integrated MDR is subdivided into four function areas. The

function areas are selected via the user interface menu bar. The
integrated MDR comprises the following function areas:
• Creating and editing message texts.

• Displaying and processing machine data.
• Creating and modifying interruptions.
• Evaluating machine data.
• Changing the time.

11.2 MDR Creating and modifying message
texts
To create or change one's own message texts, select the function

Operation - MDC - MDC message texts from the menu bar.
The "List of MDR (machine data record) message texts" mask
appears.
A list of all available message texts is displayed. You can see the
four reason types "Rest period", "Active repair time", "Maintenance
period" and "Non-productive operating time" as well as the
message text "???" when you call up the integrated MDR for the
first time. The latter is at a lower level than the reason type "Rest
period", and is automatically designated by the machine as the
reason for interruption.
Parameters The following information is displayed for each message text:

• Level: The message texts are subdivided into various levels.
The four reason types make up Level 1. New message texts
must be assigned or subordinated to one reason type or to a
preexisting message text. They are automatically assigned to a
level (ascending numbers!) lower than the original text, the
"master text".
• No.: Each message text is automatically assigned a four-digit
number. The first digit indicates the type of message text, the
other three the serial number within this type.
• Master no.: The number of the "master text".
• MDR message text: The actual text.
• Type:
Type 1: Rest period.
Type 2: Active repair time.
Type 3: Maintenance period.
Type 4: Non-productive operating time.
Softkeys:
To modify an existing message text, first select the corresponding

Modify text from the list and then press the "Modify MDR text" softkey. A
MDR text
window appears in which you can enter the new message text.
Confirm your selection with OK or cancel the procedure with
CANCEL. The four reason types and the message text "???"
cannot be changed.

New message texts can only be "appended" to existing message
Attach texts, i.e. made subordinate to them. Therefore first select the
MDR text message text to which the new text is to be attached. Then actuate
the "Attach MDR text" softkey. A window appears in which the
"master text" is displayed with the number and level. Enter the new
text in the designated field and confirm your entry with OK or cancel
the procedure with CANCEL.
The new text is added to the list below the "master text".
To delete a message text, select it from the list and then actuate the
Delete MDR "Delete MDR text" softkey. A window appears in which you are
text requested to confirm the deletion.
Confirm with OK or cancel the procedure with CANCEL. The four
reason types, the "???" message text, as well as message texts to
which further texts are subordinate can not be deleted.

11.3 MDR Displaying and editing machine
data
In the "Edit machine data" function area you can display all the
recorded interruptions of the machine operating time and issue
them as a file. You can also assign a cause (MDR message text)
to each interruption as well as split up interruptions chronologically.
You can access the "Edit machine data" function area via the
Operation – MDC – Data menu item on the menu bar of the user
interface.
Parameters: The mask shows all the recorded messages of the machine control
(PLC message) within a user-defined period of time. The following
information is displayed for each message:
• Date: The date and the precise time of the message.

• Seq: If there happen to be two or more messages with the
same date, the order in which they were issued is indicated
here.
• Status: Only two machine statuses are registered:
- Stationary: The machine has stopped for some reason.
- Running: The machine has been restarted.
• Interruption: The number of the message text. The
"stationary" message of the machine control system is
assigned the number 207 by default.
• Info: The MDR message text.
Information on a selected data record is displayed in the line above

the message window. You can see the period in time for the listed
messages as well as their amount in the line beneath the window.
Since the size of the display window is limited, only some of the
messages can be displayed if their total size exceeds that of the
window itself. The number of displayed messages as well as the
total number is displayed on the right-hand side at the bottom of
the screen. If you wish to view the remaining messages, you must
adjust the visible time window accordingly.

Softkeys:
If you have created your own interruption, i.e. divided an existing

Delete one, you can delete it by actuating the Delete interruption softkey.
interruption
Confirm your selection in the screen that now appears with OK or
cancel the procedure with CANCEL. Interruption messages that are
reported by the machine itself cannot be deleted.
If you wish to assign a new or a different message text to an

Change text interruption or divide an interruption into periods of time, select the
respective message from the list and then actuate the
Create/Modify softkey.
The "MDR Entry/Modification-Interruptions" mask appears.
You can transfer the list of messages as an ASCII file to your hard
Create drive. The information issued is precisely that information that you
file can see on the list. Simply actuate the Create file softkey.
The "MDR.txt" file is automatically created in the directory
"C:\DH\TOPSMANU.DIR\MDE\" on your hard disk. Should a file
with the name "MDR.txt" already exist in this directory, it is stored
under the name "MDR_old.txt" in the same directory if a new file is
created.
You can change the period of time for the displayed messages by
Change time actuating the Change Time Frame softkey. A screen appears, in
frame which you can enter the new time period. Confirm your selection
with OK or cancel the procedure with CANCEL.
Press the Renew display softkey to update the display.

Renew
display

11.4 MDR Creating and changing
interruptions
To ensure that machine operations are analyzed as accurately as

possible, each down time should be assigned a reason. For this
purpose, you have to select a message ("Stationary") from the
"Machine Data Record (MDR)" screen and then actuate the
Create / change softkey.
The "MDR Entry/Modification – Interruptions" mask appears.
The screen is divided into three areas.

The message text of the selected interruption message as well as
its exact time data is displayed in the "Current interruption" area.
The changes made to the interruption are displayed in the "New
interruption" area.
All the entered message texts are displayed in the form of a tree in
the "Select new interruption" area.
The four types of reasons are on the very left, all other message
texts appear in sequence below their corresponding types, offset to
the right.
Softkeys:
If you wish to create a new interruption, i.e. divide an existing

Create interruption time interval, you first have to select a message text
interruption
from the list for the new interruption and then actuate the Create
interrupt. softkey. A mask appears with the new message text and
the recorded time interval. Now enter the time of the new
interruption in the "Message time" field. (It must be within the
recorded interruption period.) Confirm your input with OK or
terminate the procedure with ABORT.
If you wish to change an interruption, i.e. assign it a different
Change message text, you must first select the new message text from the
interruption
list and then actuate the Change interruption softkey. The new
message text is transferred without confirmation of the entry and
the system switches back to the "Machine Data Register (MDR)"
screen.
You can return to the "Machine Data Record (MDR)" screen with
Return the Return softkey.

11.5 MDR Evaluating machine data
You can have all the data recorded within a self-defined period of
time evaluated and then issued as a file in the "Evaluate machine
data" function area. The overall down time, the average down time,
and the shortest and longest down times are thereby evaluated for
each message.
During the installation of the integrated MDR a so-called "Deletion
Delay" is defined in the system configuration. This means that all
messages of the machine control systems that are older than a
particular period of time are deleted automatically (stored message
texts are not affected).
Therefore evaluate the data regularly (e.g. once a week) to avoid
accidental loss of data.
You can access the "Evaluate machine data" functional area via
Operation – MDC – Evaluation on the menu bar of the user
interface.
To generate an evaluation, you must first enter the desired period
in time in the top line of the screen, as well as a designation for the
evaluation (e.g. week 12 evaluation).
Softkeys:
Then actuate the "Evaluate" softkey. The program then generates

Evaluate the corresponding evaluation and adds it to the list beneath the
input line.
To delete an evaluation, select it from the list and actuate the

Cancel "Cancel evaluation" softkey.
evaluation
Note
The data are deleted without confirmation!
To view the evaluation data, select the respective evaluation from

Display the list and then actuate the "Display list" softkey.
list

11.6 MDR Displaying the times in list form
This menu appears if you press the Display list softkey in the
"Evaluate machine data" menu.
Parameters The period in time for the evaluation is displayed in the first line of
the screen. The following information on the evaluated data is
displayed below it:
• Interr. no.: The number of the interruption message.

• Interruption text: The corresponding message.
• Quantity: the quantity of these messages within the period
• Min[h]: The shortest interruption with this message in hours.
• Max[h]: The longest interruption with this message in hours.
• Avg[h]: The average length of interruption for this message in
hours.
• Total[h]: The entire length of interruption for this message in
hours.
Softkeys:
Actuate the Create file softkey to issue the evaluation as a file in the
Create same form as can you see it on the screen.
file
The "Auswert.txt" file is automatically created in the directory
"C:\DH\TOPSMANU.DIR\MDE\" on your hard disk.
Note
Should a file with the name "Auswert.txt" already exist in this
directory, it is stored under the name "ausw_old.txt" in the same
directory if a new file is created.
Actuate the Return softkey to return to the "Evaluate machine data"
Return menu.
11.7 MDR Changing the time
You can change the current time of the operating system with the
"Change time" function, which you can access via the Operation –
MDC – Set time menu item.
Enter the new time in the field designated for this purpose and then
actuate the "Set time" softkey.

Part 3: Operating the machine
Press the FEED HOLD button first if a problem occurs while the
program is running.
The EMERGENCY STOP impact button must be pressed if work

on the machine is required because the malfunction is unable to be
eliminated by means of the control panel. Only then is it safe
enough for personnel to carry out work in order to eliminate
malfunctions.
Note
The safety guidelines in the operator's manual must be strictly
observed!
The machine may only be operated by trained personnel.

1. Switching the machine on and off
1.1 Switching on the machine
Air supply Switch on the air supply.

Switch on the main switch.
Wait until the control system is ready for operation.
Release the EMERGENCY STOP impact button.
LIGHT BARRIER flashes.
Press ACKNOWLEDGE LIGHT BARRIER.
FEED HOLD lights up.
START flashes.
Press START to acknowledge FEED HOLD.
MACHINE ON/OFF flashes.

Press MACHINE ON/OFF.
MACHINE ON/OFF lights up.
ESTABLISH HOME POSITION flashes.
Press ESTABLISH HOME POSITION.
The axes move into home position; the Z-axis first, then the X and
Y-axes and finally the rotational axes (C1 and C2).
ESTABLISH HOME POSITION lights up.

1.2 Switching off the machine in the event
of malfunctions or emergencies
Locking EMERGENCY STOP.
The machine is no longer in motion.
1.3 Switching off the machine
Prerequisites:
• No program is running.
• The punching tool is in the tool adapter.
• The machine is in JOG submode.
Press MACHINE ON/OFF.
Press EXIT WINDOWS.
The user interface of the control system is closed and Windows is

automatically ended.
Shift the main switch.
Air supply Shut off the air supply and lock it.

2. Executing a program
2.1 Executing a program automatically
Prerequisites:
• The machine is ready for operation.
• The home position of the machine has been established.
• The NC program is available in the program manager in split
form.
• Tool data has been created in the tool management of the
control system.
• The "Aborted" program status is displayed.
Select "Activity - PRODUCTION – Single job".
Press Program selection.

Program
selection
Select the program to be executed.
Press Select program:

Select
program Clamp positions or clearances are checked.
An automatic tool set-up list is created.
Press Tooling position.
Tooling
position
A dialog field appears and the tool rail can be moved to the right or
the left.
Set up the tools on the rail.
Press Acknowl. all set-up oper.
Acknowl. all
set-up oper.
Press START PROGRAM.
The rail allocation test is started.

The axes move into insertion position, the clamps open
automatically and the index pin moves up.
Insert the workpiece.

Press WORKPIECE CLAMP.
The clamps are closed and the index pin moves downwards.
Press START.
The NC program is executed.
2.2 Executing a program with the

softpunch (optional)
Prerequisites:
• The machine is equipped with the softpunch option.
• The softpunch function was programmed in the NC text.
Select "Operation – PRODUCTION – Switch elements".
Selection
Press Selection.
Select "General".
Press TOGGLE.
Select the "Softpunch" switch element.
Press TOGGLE.
The softpunch function can be activated or switched off at any time

during processing using this switch element.

2.3 Triggering a single stroke
A single stroke is used to:
• Punch out a workpiece or separate a scrap skeleton

• Check formed sections.
Prerequisites:
• A tool is in the tool adapter.
Select "Operation – SET-UP – Switch elements".
Selection
Press Selection.
Select "Punching".
Press TOGGLE.
Select the "Single stroke on" switch element.
Press TOGGLE.
The working position is established.

The tool is checked.
A single stroke is triggered.

2.4 Changing the forming depth
Press FEED HOLD if the active program is already being

executed.
Recommendation: If possible, do not perform a program stop
during a tool change.
The FEED HOLD button lights up.
The START button flashes.
Select the "PRODUCTION - Tables - Tool technology" control
area.
Press Program name.

Program
name
Open the selection field with TOGGLE.
Select an active NC program.
Press TOGGLE.
Press Table name.

Tab. name
Open the selection field with TOGGLE.
Select the technology table for forming.
Press TOGGLE.

Press Parameters.
Parameters
Enter a value for the required forming depth in mm in the "Plunge

position offset (LDP)" parameter. The plunge depth of the tool in
the sheet is reduced by entering a negative values and increased
by entering a positive value.
Press START.
The machine continues to operate with the changed forming depth.
2.5 Program stop during execution
The machine can be stopped in order to perform checks.
Prerequisites:
• A program is being executed.
Press FEED HOLD.

The FEED HOLD button lights up.
The machine is now at a standstill.
Checks can be carried out.
ACKNOWLEDGE LIGHT BARRIER flashes.
START flashes.
Press START to acknowledge FEED HOLD.
The machine resumes operation.
2.6 Stopping programs
The following operating steps should be carried out if a running NC

program is to be stopped and not resumed:

Press FEED HOLD.

FEED HOLD lights up.
The machine is now at a standstill.
Press RESET.
The "Aborted" program status is displayed.

The execution of the production plan is switched to "inactive" to
prevent the next program from being immediately started.
2.7 Reentry into a program
Prerequisites:
• A program was aborted while it was running.
• Any active errors or malfunctions have been rectified.
• The light barrier has been acknowledged.
Select "Operation - PRODUCTION - Single job".
Press Re-entry.
Re-entry

A dialog window appears. You can define the point of re-entry in
this window.
The following options are available for selection.
• Interruption point.
• Next machining.
• Last machining.
• Last tool change.
• Next tool change.
• Specific tool change.
Use the softkey to select the desired point of entry. In this

Interruption example, press the Interruption point softkey.
point
The "Distance to point of interruption" dialog window is opened.

Select the desired point of entry with the softkey.
Simulation with jump technique: Simulation with jump
technique can be selected if the following requirements are met:
• The main program needs to have been programmed
absolutely.
• The "ENTRY LASER" comments created by the TruTops
programming system must be available.
"Simulation with jump technique" may not be selected if one of
these requirements has not been met. In this case, the simulation
takes significantly more time since the complete program has to
be run through.
Press OK.
OK
Press START.
The required tool is installed.

Press START.
The program is resumed.

3. Working with the production plan
3.1 Creating a production plan
Prerequisites:
• NC programs are available in the program manager in split
up form.
Press Production plan.

Production
plan
Press Select program.

Select
program
Select the NC program to be added to the production plan as sheet

job.
Create sheet
Press Create sheet job.
job
Enter the job data.

Press Create sheet job.
Create sheet
job
The "Sheet job was created" message appears in the message

line. Repeat the steps until all NC programs to be added to the
production plan have been stored as sheet jobs.
Production
plan
All the created sheet jobs are displayed in the production plan in
the order of their sequence numbers.

3.2 Executing a production plan
Prerequisites:
• The production plan has been created.
• The appropriate status has been set for each sheet job in the
production plan.
• The tools are in the control system's tool management.

Production
plan
Press Prepare production.

Prepare
production
The screen switches to the automatic tool set-up list.

An automatic tool set-up list is created for all sheet jobs with "free"
and "paused" statuses.
Tooling
position
The dialog field is opened and the tool rail can be moved to the
right or left.
Set up the tools.
Acknowl. all
set-up oper.
The screen switches to the production plan.

Press Production Start/Stop.
Start/Stop
production
The rail allocation test is started.


Press START.
The execution of the production plan is started.
3.3 Restarting the execution of the

production plan after a program
interruption
Prerequisites:
• Execution of aborted program is not to be resumed.

Production
plan
The execution of the production plan is set to inactive in the

"Production plan" menu
Press Production Start/Stop.
Start/Stop
production
The execution of the next NC program is prepared:

• The rail allocation test is started.

Press START.
The execution of the production plan is resumed.
4. Moving the axes manually
Prerequisites:
• FEED HOLD is not active.
• No NC program is running.
• The feed rate potentiometer is set to > 0 %.
Select "Operation - SET-UP - Jog mode".
The "JOG mode" submode and "continuous" travel characteristic

have been selected.
Press the softkey for the axis to be moved.
X, Y, Z
The selected axis softkey lights up in yellow.
Move the axis with the JOG keys.

5. Releasing the drive brakes
5.1 Releasing the X and Y axis drive

brakes
Prerequisites:
• Emergency stop active.
Select "Operation - SET-UP - Switch elements".
Selection
Press Selection.
Select "General".
Press TOGGLE.
Select the "Release brakes X, Y" switch element.
Press TOGGLE.

6. Manual execution of the lubrication
cycle
Prerequisites:
Select "Operation - SET-UP - Switch elements".
Selection
Press Selection.
Select "General".
Press TOGGLE.
Select the "Lubricate pinion" switch element.
Press TOGGLE.
The lubrication cycle is started for the lubrication of all pinions (X,
Y, Z and C drives).

7. Diagnostic functions
7.1 Fault diagnostics
The fault diagnostics feature can be used to investigate the cause,

effect, and location of errors indicated by messages generated
when working on the machine. Measures for eliminating the errors
are also displayed.
Select "DIAGNOSTICS - Fault diagnostics".
An overview list of all current error messages is displayed.
Select the error message you wish to find out more about.
Press Error location.

Error location
The error location screen is displayed together with measures to

be taken to eliminate the error and comments.
Press Cause.
Cause
A text on the cause and effects of the error is displayed.

7.2 Displaying machine inputs and outputs
Select "DIAGNOSTICS - I/O diagnostics".
Press Selection.
Selection
Open the selection field.
Select basic machine.
Press ENTER.
All inputs and outputs appear on the displayed screen. The display
is explained with an example:
Example It is to be checked whether the second bit of input E33 has been
set:
Press the keys until the green bar reaches column E33.
<< >>
The eight bits of input E32 are displayed in a column, and under
them the eight bits of input E33.
The second bit of input E33 is set (1 = high).
The corresponding text can be viewed on the right.

7.3 Remote diagnosis via pcANYWHERE 1
Prerequisites:
• Modem connection (telephone).
• Modem
• pcANYWHERE remote diagnostics software.
After the remote diagnostics on the TruPunch 5000 control system

has been activated, a TRUMPF employee can operate the control
over the telephone line and localize and eliminate problems that
occur. The remote diagnostics must be activated onsite at the
control system:
Select "DIAGNOSTICS - Remote diagnostics".
The initial screen of the remote diagnostics software appears.
Press Start.
Start
The following procedures then take place automatically:

• A TRUMPF technician dials up the machine via modem.
• Log in with the user ID and password.
• The machine checks the user ID and password.
A modem connection is established between TRUMPF and the
customer.
Press Menu.
Menu
to:
• Receive written messages from the TRUMPF technician
(remote PC) or send written messages to the TRUMPF
technician (host PC) via "Dialog".
• Interrupt the telephone connection via "Exit session".
1
Symantech registered trademark.

7.4 Querying the software version
Select "DIAGNOSTICS - Service - MMC version".
The software version of the user interface is displayed.
Select "DIAGNOSTICS - Service - NCK/PLC version".
The software versions of NCU and PLC are displayed.
8. Managing master files
8.1 Uploading NC programs from the

USB interface
An NC program is stored as a master file on a USB memory stick;

before it can run on the machine, it must be split and loaded into
the program manager of the control system.
Connect the USB memory stick.
Select "Operation - PROGRAMMING - File management".
Select drive (H:\ or G:\) for USB memory stick.
Press ENTER.
Select the desired program with the CURSOR keys or the mouse.
Press Split master file.

Split
master file
The master file is split up into main programs, subroutines and

table entries and is stored in the program manager of the control
system.

8.2 Uploading NC programs from the
hard disk
An NC program is stored as master file on the hard drive in the

directory C:\DH\TOPSMANU.DIR and is to be split up and
transferred to the program manager of the control system in order
to be executed on the machine.
Select the drive column using the FOCUS key.
Select the "C:\DH\TOPSMANU.DIR" drive using the CURSOR

keys.
Press ENTER.
The contents of the hard drive are read and displayed.
Select the desired program using the CURSOR keys.
Press Split master file.

Split
master file
The master file is split up into main programs, subroutines and

table entries and is stored in the program manager of the control
system.

8.3 Output of NC programs via
USB ainterface
An NC program is split up into main programs, subroutines and

tables in the program manager of the control system and is to be
saved as a master file on a USB memory stick.

Press Output program.
Output
program
Press Generate master file.

Generate
master file
Enter path "H:\Programname.Ist".

Press OK.
OK
A master file with all main programs, subroutines and tables is

created and saved on the USB memory stick with the extension
".lst".

8.4 NC program output on the hard
disk drive
An NC program is located in the program manager of the control

system, split up into main programs, subroutines and tables, and is
to be archived as master file on the hard disk drive at
"C:\DH\TOPSMANU.DIR".

Output
program
Press Generate master file.

Generate
master file
Enter the path "C:\DH\TOPSMANU.DIR\program name.lst".

Press OK.
OK
A master file is generated with all main programs, subroutines and

tables and saved on the hard drive with the extension ".lst".

8.5 Program part output via USB interface
A program part (main program or subroutine) is to be saved on a

USB memory stick.

Output
program
Select the desired program part (main program or subroutine) with

the CURSOR keys.
Press Copy file.

Copy
file
Enter the path "H:\programname".

Press OK.
OK
The program part is stored on the USB memory stick.

8.6 Deleting NC programs from the
program manager
An NC program is stored in the program manager of the control

system in split form and is to be deleted together with all program
parts and table entries.
Select "Operation - PROGRAMMING - NC program management".
Press Delete MP + SR.

Delete
MP+SR
Press OK.
OK
The NC program is erased from the program manager of the

control system, together with all of its program parts and table
entries.
If the NC program is additionally stored as a master file in the file
manager of the control system, the master file must be deleted
there separately:
Press Delete file.

Delete file
Press OK.
OK
The master file is deleted from the file manager of the control
system.

9. NC program management
9.1 Displaying NC text
The NC text of a program part (main program or subroutine)

should be displayed in the NC Editor.
Prerequisites:
• The NC program is stored in the program manager of the
control system, split up into main programs, subroutines, and
table entries.
Select "Operation - PROGRAMMING - NC program management".
Press Editor.
Editor
If an NC program consists of several parts (main programs and

subroutines), the correct program has to be selected once again
from the displayed list.
Press Editor.
Editor
The NC text of the selected program part is displayed in the NC

Editor.

9.2 Editing NC text
Searching for a block in the NC text
The program block with number N100 is to be searched for in the

NC text.
Prerequisites:
• The NC text is displayed in the editor.
Press Search/Replace.
Search/
Replace
7 8 9 Enter N100 in the input field.

4 5 6
1 2 3
0
Press OK.
OK
N100 appears in the NC text, marked in red.

Searching for a function in the NC text
The NC text is to be searched for the G90 function.
Prerequisites:
Search/
Replace
7 8 9 Enter G90 in the input field.

4 5 6
1 2 3
0
Press OK.
OK
G90 appears in the NC text, marked in red.

Press Search/Replace Next if you have not yet found the text
Search/Repla passage you are looking for.
ce Next
Searching for and replacing a function in the

NC text
The G00 function is to be searched for in the NC text and replaced

by the G01 function.
Prerequisites:

Search/
Replace

4 5 6
1 2 3
0
Press OK.
OK
G00 appears in the NC text, marked in red.

Search/
Replace
Press Replace.
Replace
The softkey lights up in yellow.

4 5 6
1 2 3
0
Press OK.
OK
The function G00 is replaced by the function G01.

Inserting an additional line
An additional line is to be pasted into the NC text.
Prerequisites:
Position the cursor bar at the start of the block, where you want to
insert an additional line.
Press ENTER.
The line is inserted.

Copying and inserting text passages
Several lines of the NC text are to be copied and inserted

somewhere else.
Prerequisites:
Position the cursor bar at the start of the block at which you wish to
begin your selection.
Keep the SHIFT key pressed and mark the text you wish to copy
using the CURSOR keys.
SHIFT +
The text appears in red.

Press Copy.
Copy
Position the cursor bar at the start of the block, where you wish to
insert the copied text passage.
Press Insert.
Insert
The copied text is inserted.

Deleting text passages
A block, word or character is to be deleted from the NC text.
Prerequisites:
Position the cursor bar at the beginning of the text passage you
wish to delete.
Keep the SHIFT key pressed and mark the text you wish to delete
with the CURSOR keys.
SHIFT +
The text appears in red.
Press Cut out.

Cut
out
The text passage is deleted but can be repasted at any point in the
NC text.
10. Editing tables based on NC text
If the programming of the machine sequences or technology tables

are to be edited later in the NC text, this is usually done by editing
table parameters:
• Removal of parts (TC_PART_UNLOAD).

• Loading sheet (TC_SHEET_LOAD).
• Unloading sheets (TC_SHEET_UNLOAD).
• Sheet technology (TC_SHEET_TECH).
• Repositioning (TC_SHEET_REPOSIT).
• Tool technology (TC_TOOL_TECH).
The table parameters for the active program can also be edited
while the program is running. All changes take effect the next time
the respective table is called up.

Exception: The parameter changes to tool technology tables take
immediate effect. Therefore, FEED HOLD must be active while the
table is edited. Press START to continue work after making the
changes.
The procedure for calling up tables is identical for all types of

tables:
Prerequisites:
Position the cursor bar directly in front of the relevant table call-up
instruction in the NC text.
Press TOGGLE.
The table is displayed.
Press Parameters.
Parameters
Edit the desired parameters.
Press NC Editor.
NC Editor
The changes made to the table are saved and transferred to the
NC.

11. TOOLING
11.1 Creating an automatic tool table and

loading the tool rail
Prerequisites:
• The NC program is in the program manager, split up into
main program, subroutines and table entries.
• The punching tools required for execution are either in the
tool store or on the tool rail.
Select "Operation - TOOLING - Automatic set-up list".

Press Select program.
Select
program
Select the program to be executed.
Press Create set-up list.

Create
set-up list
An automatic tool set-up list is created.

Tooling
position
A dialog field appears and the tool rail can be moved to the right or
the left.
Set up the tools on the rail.
Acknowl. all
set-up oper.
The rail allocation is updated.
The tool set-up procedure is ended.
Note
If the tool data of individual tools is not correct, you can correct it
with the Change tool data softkey. You can change the following
parameters in this way: Regrind length, whisper tool yes/no,
presser foot type, sheet thickness and TDC forming height.

11.2 Manually loading/unloading tools
Tools should be replaced on the tool rail by means of the manual

tool set-up list.
Select "Operation - TOOLING - Tool table (manual)".
Use the CURSOR keys to select the tool from the tool list (top) that
you wish to remove from the tool rail (tools with tool station S).
Press ENTER.
The tool appears in the tool set-up list (below).

Repeat this procedure until all tools to be unloaded appear in the
tool set-up list.
Use the CURSOR keys to select the tool from the tool set-up list
(above) which you wish to load from the store onto the tool rail
(tools with tool station L).
Press ENTER.
The tool appears in the tool set-up list (below).

Perform the tool set-up operations.

Acknowl. all
set-up oper.
The rail allocation is updated.

Press Delete set-up list.
Delete
set-up list
There are no longer any active manual tool set-up operations.

11.3 Loading a tool from the rail onto the
ToolMaster (optional)
Select "Operation – TOOLING - Tool table (manual) - Set up rail

TOOL".
Press the focus key to switch to the upper section of the screen, in
which the current rail allocation is displayed.
Select a tool or an empty rail station with the CURSOR keys.
Press ENTER.
The selected rail station is displayed on the left side in the upper
white field next to the rail allocation.
Use the CURSOR keys to select a tool or an empty tool station
from the current tool allocation.
Press ENTER.
The selected tool station is displayed on the left, in the lower white
field next to the rail allocation.
Press Create.
Create
The tooling pair that has just been formed is added to the retooling
list.
Repeat the procedure until all tools to be relocated are displayed
as tooling pairs at the bottom left in the tool set-up list.
Press Start tool set-up.
Start
tool set-up
The tooling procedure between the ToolMaster and the tool rail is
started.

11.3 Correcting clamp positions
Select "Operation - TOOLING - Rail allocation".

Press Program technology.
Program
technol.
The "NCP technology data" menu appears.
Press TOGGLE.
Press TOGGLE.
The required clamp positions are displayed.
Memorize the displayed clamp positions.

OK Press OK.
Damage to the clamp hose when displacing clamps.

¾ Lift the clamp hoses out of the guide before moving them.
¾ Do not kink the clamp hoses.
Caution
¾ Replace clamp hoses which are damaged with, for example,
kinks or abrasions.
Load the clamps onto the required rail stations with the Re-locate,
Re-locate Load/Unload clamp softkeys.
clamp

11.4 Removing an active tool
A tool which is in the tool adapter is to be set up on the tool rail.

Press Change curr. tool.
Change
curr. tool
Press Remove active tool.

Remove
curr. tool
11.5 Unloading all tools

Press Unload all tools.
Unload
all tools
12. Operating the integrated MDR
All machine runtimes and downtimes are automatically recorded by

the integrated machine data register (MDR). The recorded
downtimes (interruptions) can be assigned an interruption cause in
the form of a message text. Each message text must be assigned
to one of the basic reason types.
Note
For more information, refer to chapter "Operation", section
"Integrated MDR activity (optional)".

12.1 Creating a message text
New message texts can only be "attached" to message texts which

already exist. The message text to be newly created is made
subordinate to an existing message text.
Select Operation > Page in/out > MDR message text.
Select the message text to which a new message text is to be

made subordinate.
Press Append MDR text.

Attach
MDR text Enter the new message text in the input field.
Press OK.
OK
The new message text appears in the list under its higher-level
message text.
12.2 Assigning a message text
In order for the downtimes of the machine to be evaluated

properly, each downtime must be assigned an interruption cause
(message text).
Select Operation > MDR > Data.

The "Machine Data Register (MDR)" screen is opened. A list is
displayed of all message texts during the entered period.
Select an interruption ("Stationary" message) to assign a message
text to.
Press Change text.

Change
text The "MDR Entry/Modification - Interruptions" screen is opened.

Select a message text.
Press ENTER.
Press Change interruption.

Change
interruption The message text is assigned to the interruption.
12.3 Splitting up an interruption period
A downtime period can be split up into several time intervals and

each time interval assigned an interruption cause (message text).
Select Operation > MDR > Data.
Select an interruption ("Stationary" message) of which the time

interval is to be split up.
Press Change text.

Change
text The "MDR Entry/Modification - Interruptions" screen is opened.
Select a message text.
Press ENTER.
Press Create interruption.

Create
interruption Enter the start and end time in the "Meldungszeit (Message time)"
input field.
Press OK.
OK
The time interval and interruption cause are included in the list of all
recorded interruptions.

12.4 Evaluating machine data
The list of all downtimes during a given period can be displayed

and saved as a file.
Select Operation > MDR > Evaluation.

The "Evaluation of Machine Data" screen is opened.
Enter the period of time in the "From" and "To" input fields. Enter
the title in the "Remark" input field.
Press Evaluate.
Evaluate
The title and period of time are displayed in the list field.
Select Evaluation.
Press Display list.

Display
list All downtimes within the period are listed on the screen.
Press Create file.

Create
file The list is saved as 'Auswert.txt' file in the
'C:\DH\TOPSMANU.DIR\MDE' folder.
Note: If a file with the name "Auswert.txt" already exists in this

directory, it will be renamed "ausw_old.txt" when the new file is
generated.

13. Adjusting the pressure foot pressure
1 2
1 Pressure gauge 3 Pin with manual intervention

2 Rotary button function
Pressure reducing valve Fig. 32211
The presser foot pressure can be changed in two ways.
Adjusting with manual 1. Press and hold the pin on the underside.
intervention function
2. Adjust presser foot pressure using the rotary button.
The presser foot pressure is displayed on the pressure gauge.
Adjusting without manual Prerequisites

intervention function • Punch with active presser foot.
• Presser foot pressure < 20370 N.
• Program start of a program with presser foot
pressure <20370N.
¾ Adjust presser foot pressure using the rotary button.

The presser foot pressure is displayed on the pressure gauge.

14. If problems arise
14.1 Removing stripper from stripper

adapter
In rare cases, the stripper can jam in the stripper adapter.
Note
The machine is switched on during the following maintenance
work.
The punch must also be taken out for long and angled punches.
Risk of injury when carrying out maintenance work when

the machine is switched on!
¾ Attach e.g. a warning sign to the control panel to indicate
Danger that maintenance work is being carried out or appoint a
custodian.
¾ Make sure nobody is within the danger zone before starting
the machine.
1. Select "Activity - SET-UP - Switch elements."

2. Select "Punching" switch element.
3. Select "Tool clamp OPEN" parameter.
The tool clamp opens.
4. Push the blocker (part no.1230669) between the thrust pieces
of the stripper clamp and the deflector collar so that it is free
from backlash.

1
1 Stripper clamp thrust piece 3 Deflector collar

2 Blocker
Blocker Fig. 33326
5. Press EMERGENCY STOP.

6. Raise stripper adapter latches to the left and right and remove
the stripper from the stripper adapter.

14.2 Removing the punch from the
punching head
In rare cases, the punch may jam in the punch adapter. This could
be caused, for example, by excessive heating of the punch or the
punch adapter or by overtightening the head screw of needle
punches.
In the following, a distinction is made between two cases:

• Case 1: The punch clamp does not open.
• Case 2: The punch is jammed despite the punch clamp being
open.
Situation The machine is in automatic operation (activity "Production"). The

error message "Tool sensor system 1" is displayed during tool
removal.
Note
work.

¾ Attach, for example, a warning sign to the control panel to
Danger indicate that maintenance work is being carried out or
appoint a supervisor.
the machine.
Remedy 1. Cancel program by pressing the RESET button.

2. Select activity "SET-UP - Switch elements."
3. Move the Y axis in the + Y direction.
5. 1st case: "Tool clamp open" is pending, but the punch clamp
does not open mechanically:

1 2 3
1 Clamping piece 3 Screwdriver

2 Alignment ring
Fig. 30723
¾ Use a screwdriver to press the clamping piece upwards.

¾ Blocker
¾ Raise the stripper clamp latches and remove both the stripper and
punch.
or
6. 2nd case: The punch is jammed despite the punch clamp being
open:
¾ Move the punching head to the highest position.
¾ Tilt the chute for small parts.

1 2
1 Copper mandrel
2 Punch
Fig. 30722
¾ If possible, remove the stripper by hand. Use blocker.

¾ Press EMERGENCY STOP.
¾ Use a hammer and copper mandrel to carefully release the
punch and remove it (if necessary together with stripper).
7. Press the ESTABLISH REFERENCE POINT button.
8. Select activity "TOOLING".
9. Press Change curr. tool and then Punching head empty.
10. Confirm question "Does the punching head really have no
tool?" with OK.
The next tool change is a slow tool change.

14.3 Removing the die from the die holder
In rare cases, the die can jam in the die holder.

• Operating tool 0980847.
• Copper mandrel.
Note
work.

the machine.
If the clamp is not open, then if necessary:

1. Setup – Switch elements – Punching – Highest position.
2. Open Setup – Switch elements - Clamp.
3. Dismantle brush field behind the die holder (2 screws).
4. If necessary, use operating tool.
5. If necessary, tighten the operating tool, until the die clamping
piston moves down.
7. Remove the service tool.
8. Remove the die.
9. Install the brush field.
10. Select activity "TOOLING".
11. Press Change current tool and then Punching head empty.

14.4 Replacing the stripper segment
Note
work.

the machine.

• Stripper segment mat. no. 917997.
• Screws M4x16 4x mat. no. 014435.
1. Select activity "SET-UP - MDA."

2. Enter C1=DC (205).
3. Press ENTER.
4. Enter M30.
5. Press ENTER.
6. Press Start.
8. Select selection menu "Punching".
9. Press "Highest position" switch element.
The punching head moves to the highest position.
11. Release screws on defective stripper segment.
12. Remove stripper segment.
13. Install a new stripper segment.
14. Secure stripper segment screws with Loctite and tighten.
15. Release EMERGENCY STOP.
18. Select "Tool change height" switch element.
This moves the punching head to the tool-change height.

15. Using ShearMaster (optional)
Switch element Description
1. Establish home position Move blade up and conveyor belt back.

Active: ShearMaster is in home position.
2. Start Start ShearMaster.
Cut up scrap skeleton and move into home position.
Active: ShearMaster is started.
3. Jogging +/- Gradually actuate ShearMaster with + (forwards) or –

(backwards).
4. Sheet format The conveyor belt moves automatically depending on the
programmed sheet format into the optimal position (small,
medium, large or outsize).
The programmed format can be manually set to a larger format
than programmed.
5. Stacking mode Switch off ShearMaster and stack scrap skeletons on the
conveyor table.
Functions of the ShearMaster switch element Table 4-1
15.1 Starting and stopping ShearMaster

manually
In order for manually placed scrap skeletons to be cut up, the

ShearMaster must be manually started and stopped.
Starting manually 1. Select SETUP.

2. Select Switch element group ShearMaster.
3. 2. Select Start and press TOGGLE.
The ShearMaster starts.
Stopping manually 4. Press RESET .

ShearMaster stops.
Establishing the home 5. Select 1. Establish home position and press TOGGLE.
position

15.2 Change scrap container
Tilted sheets in the scrap container

Risk of injury
¾ Wear gloves.
Warning
The scrap container is equipped with level monitoring. If the

container is full, a message is issued.
1. Release the brakes on the container.

2. Pull out the container under the ShearMaster.
3. Push the other container in.
4. Engage brakes on the container.
5. Acknowledge the light barrier.
15.3 Use ShearMaster in stacking mode
Sheets up to 4 mm (stainless steel, aluminum) or 6.4 mm (mild

steel) can be cut up with the ShearMaster. With thicker sheets, the
scrap skeletons can only be stacked on the conveyor table, but not
broken up. The stacked scrap skeletons must be removed
manually.
Note
The ShearMaster must not be started if more than one scrap
skeleton/sheet is lying on the conveyor table.
The stack height monitoring sensors only recognize if the
maximum height of the stacked scrap skeletons has been reached.
1. Select Setup.
2. Select Switch element group "ShearMaster".
3. Select 5. Stacking mode, active.

15.4 Technical notes
• Turn the nesting of the sheet by 180°, if long inner cutouts are
present in the scrap skeleton. They tend to bend downward,
which could push the scrap skeleton onto the shears and not
the conveyor table.
• If parts of long, narrow slats remain on the lower blade after
separation, it can cause the ShearMaster to switch off due to
overload from the sheet parts lying on top of each other.
Relevant at sheet thicknesses > 3 mm.
15.5 Correcting malfunctions
Release tilted scrap skeleton
Tilted sheets
Risk of injury
¾ Wear gloves.
Warning
If a sheet is tilted in the ShearMaster, the scrap skeleton must be

moved out backwards before the tilted sheet can be removed.
Note
If the scrap skeleton is not cut up into four parts, it can also
become tilted. If this problem occurs frequently, the lateral stops on
the blade slide must be readjusted (notify TRUMPF service).
Release scrap skeleton 1. Select Setup.

2. Select Switch element group "ShearMaster".
3. Either
¾ Approach the home position.
¾ Select Toggle.
Move blades up. The conveyor belt moves into home
position and pulls out the tilted scrap skeleton.
or
¾ Select Jog.
¾ Move the blades with – up.
¾ Remove scrap skeleton manually.

Release tilted scrap from the chute
Tilted sheets
Risk of injury
¾ Wear gloves.
Warning
Note
The scrap container is equipped with level monitoring. If scrap
parts are tilted in the scrap container, a message is issued
(container full). Visually inspect the chute regularly.
¾ Empty the scrap container.

or
¾ Carefully remove tilted sheet metal parts.

16. Using height-adjustable clamps
16.1 Moving height-adjustable clamps
1 2
3 4
1 Height-adjustable clamp 3 Thrust piece

2 Clamping screw clamp 4 M8 screw in the mounting
3 Thrust piece segment
Height-adjustable clamp Fig. 41800
Damage to the clamp hose when displacing clamps.

¾ Lift the clamp hoses out of the guide before moving them.
¾ Do not kink the clamp hoses.
Caution
¾ Replace clamp hoses which are damaged with, for example,
kinks or abrasions.

1. Undo the clamping screw clamp.
2. Move clamp into desired position.
3. Tighten the clamping screw clamp.
4. Check the position of the hoses in the hose channel.
16.2 Utilizing height-adjustable clamps
The clamps can be damaged when cleaned with compressed

air!
The clamp guides can become soiled or damaged.
Caution ¾ Do not clean clamps with compressed air under any
circumstances.
¾ Clean the clamps with a lint-free cloth that has been dipped
in oil.
Damage can occur when clamps collide with the sheet!

The clamp guides can become damaged.
¾ Work without thrust pieces as much as possible.
Caution
¾ Place at least three height-adjustable clamps at different

positions on the sheet.
16.3 Help if problem arises
1. Check M8 screws in the mounting segment with a torque

wrench at 40 Nm. This was stretched if the screw was loose.
2. Use new screws.
3. Check the ease of vertical movement. If this is limited,
contact Technical Customer Service at TRUMPF.

Chapter 5
Maintenance of the machine

3. Lubrication ..................................................................... 5-8

3.1 Overview .......................................................................... 5-8
Longitudinal and transverse guides.......................... 5-11
Transverse carrier and table support bearings......... 5-13
Hydraulics ................................................................. 5-15
Zero stop sensor (only TruPunch 5000 with
automation)............................................................... 5-20
Die spray lubrication (optional) ................................. 5-24
Tapping lubrication unit (optional) ............................ 5-26
Die clamping piston clamp........................................ 5-30
Rail transverse carrier and table support ................. 5-31
Punch holder............................................................. 5-32
Active die (optional) .................................................. 5-32

4. Hydraulic system ......................................................... 5-34
4.1 Overview ........................................................................ 5-34
4.2 Depressurizing the accumulator system........................ 5-35
Hydraulic accumulator .............................................. 5-37
Hydraulics hose lines................................................ 5-41
Hydraulic unit ............................................................ 5-43
5. Pneumatic system ....................................................... 5-46

5.1 Overview ........................................................................ 5-46
Air cushions (optional) .............................................. 5-47
6. Mechanical elements................................................... 5-50

6.1 Overview ........................................................................ 5-50
Punching tool adapter............................................... 5-51
Chip vacuum system: side channel blower .............. 5-52
Chip vacuum system: vacuum pipe.......................... 5-54
Chip vacuum system: chip flap................................. 5-55
Chip vacuum system, complete................................ 5-57
Tool cartridge support slat ........................................ 5-59
Clamps...................................................................... 5-60
Racks and guide rails ............................................... 5-61
Index pin(s) ............................................................... 5-61
Brush field segment tables, parts flap and brush
tables (optional) ........................................................ 5-62
Brush field segment tables ....................................... 5-64
Compressed air maintenance unit............................ 5-67
Control panel ............................................................ 5-68
7. Electrics ........................................................................ 5-69

7.1 Overview ........................................................................ 5-69
Switch cabinet: connectors and clamping screw
connections............................................................... 5-70
Switch cabinet: external air circuit ............................ 5-70
Switch cabinet: NCU battery..................................... 5-71
Buffer battery box PC ............................................... 5-73
Safety light barrier and light barrier parts flap
(optional)................................................................... 5-76
Inductive proximity switch......................................... 5-77
Sensor system - stripper sensor............................... 5-78
8. Cooling unit ................................................................. 5-82

9. Procedure after a collision ......................................... 5-87
10. Handling the setting device ........................................ 5-88

10.1 Assigning the punch and alignment ring........................ 5-88
10.2 Determining the tool length............................................ 5-90
11. Regrinding tools .......................................................... 5-91

11.1 Compensating the regrind amount ................................ 5-92

1. General guidelines
Correct maintenance is a prerequisite for maintaining the quality of

the machine. It prevents operational malfunctions and their
consequences.
Risk of fatal injury during maintenance work with the

machine switched on!
¾ Unless expressly stated otherwise:
Danger – Switch off the MAIN SWITCH.
– Lock the MAIN SWITCH.
– Pull out the key.
¾ Strictly observe the safety regulations.
Notes on cleaning • The entire system should be cleaned at regular intervals.

• Brush off large particles of dirt or remove them with an
industrial vacuum cleaner.
Notes on lubrication Refer to the lubrication chart and maintenance instructions for the
lubrication of the machine. The following points should also be
observed:
• Do not leave filler and drainage caps open for longer than
necessary and keep them clean.
• Drain waste oil only at operating temperature.
• Oil chambers and lubricating points should only be cleaned
using lint-free cloths and mineralized oils ISO VG3 – VG10. Do
not use cleaning wool, kerosene or benzene.
• Do not mix synthetic lubricating oils with mineral oils or
synthetic oils from other manufacturers, even if the synthetic oil
in question has equivalent properties.
• Dispose of waste oil appropriately.
5-4 1BGeneral guidelines B380EN05.DOC

2. Maintenance overview
Interval Maintenance point Maintenance work Page

(operating
hours)
8 Punch spray lubrication Checking the oil level 21
8 Die spray lubrication Checking the oil level 24
8 Punching tool adapter Cleaning 51
8 Chip vacuum system: chip flap Cleaning 56
8 Index pin(s) Cleaning 61
40 Hydraulic unit Checking the oil level 15
40 Spray lubrication tapping Check oil jet 26
40 Spray lubrication tapping Checking the oil level 26
40 Chip vacuum system: vacuum pipe Clean strainer and filter 54
40 Chip vacuum system: chip flap Check sealing ring and replace if 56
necessary
40 Rail transverse carrier and table support Clean and lubricate rail 31
40 Racks and guide rails Check and clean 61
40 Tool cartridge support slat Clean support slat 59
40 Compressed air maintenance unit Check pressure and adjust if necessary 67
40 Sensor system - stripper sensor Cleaning 78
160 Central lubrication Check filling volume or refill oil 14
160 Oil cooler Cleaning 45
160 Chip vacuum system, complete Check low pressure 57
160 Clamps Check cutting rings and replace if 60
necessary
160 Cooling unit Check water level 83
160 Cooling unit Check filter mats 85
500 Spray lubrication tapping Replacing hose seal 29
500 Compressed air maintenance unit Switch off the machine 68
500 Punch holder Lubricate 32
500 Air cushions Check air pressure 47
500 Safety light barrier and light barrier parts flap Cleaning 76
100 Die clamping piston clamp Lubricating grease nipples 30
1000 Hydraulic accumulator Check initial pressure and top up 38
nitrogen if necessary
Every 6 months Cooling unit Replace the water 83
Every 6 months Cooling unit Replace filter mats 83
2000 or at least Longitudinal and transverse guides Lubricating grease nipples 11
once a year
2000 Transverse carrier and table support bearings Lubricating grease nipples 13
2000 Hydraulic unit Analyze hydraulic oil 15
B380EN05.DOC 2BMaintenance overview 5-5

(operating
hours)
2000 Zero stop sensor (only TruPunch 5000) Lubricating grease nipples 20
2000 Hydraulic hose lines Check 41
2000 Stripper rod pressure diaphragm accumulator Replace diaphragm accumulator 39
2000 Chip vacuum system: side channel blower Clean protective screen and foam 52
material filter
2000 Switch cabinet: connectors and clamping screw Check 70
connections
2000 Compressed air maintenance unit Replacing the filter cartridge 68
2000 Switch cabinet: external air circuit Cleaning 70
Every three Switch cabinet: NCK battery Replace 71
years
Every five years Switch cabinet: buffer battery box PC Replace 73
Every five years Hydraulic unit Change hydraulic oil 16
As needed Hydraulic unit Replacing oil and air filters 43
As needed Die spray lubrication Fill the supply line with oil 24
As needed Punch spray lubrication Refill oil 22
As needed Punch spray lubrication Bleed 23
As needed Spray lubrication tapping Bleed 27
As needed Spray lubrication tapping Refill oil 28
As needed Punch spray lubrication Setting the oil quantity 48
As needed Brush field segment tables Adjusting the height 64
As needed Control panel Check filter mats and replace if 68
necessary
As needed Cooling unit Top up with water 83
As needed Sensor system - stripper sensor Adjust with new device 79
Regularly Hydraulic accumulator Check 37
On replacement Inductive proximity switch Checking 77
If heavily Brush field segment tables, parts flap and brush Cleaning 62
contaminated tables
When the control Active die Replacing a cartridge 32
unit sends a
message
Table 5-1
5-6 2BMaintenance overview B380EN05.DOC

For single-shift operation:
8 operating hours Daily

40 operating hours Weekly
160 operating hours Monthly
500 operating hours Every three months
1000 operating hours Every 6 months
2000 operating hours Once a year
5000 operating hours After 2½ years
Every five years After 5 years, regardless of the number of
operating hours.
Table 5-2

3. Lubrication
3.1 Overview
1 Transverse carrier support 6 Punch spray lubrication 11 Die spray lubrication

2 Longitudinal and transverse 7 Die clamping piston clamp 12 Active die
guides 8 Hydraulic system Y years
3 Central lubrication 9 Tool rail M When the control unit sends a
4 Spray lubrication tapping 10 Punch adapter message
5 Zero stop sensor
Fig. 55149
5-8 3BLubrication B380EN05.DOC

Symbol Explanation Symbol Explanation
Indication of lubrication intervals in Monitor oil level and, if necessary, top
operating hours up to required level
Read the maintenance instructions Checking the oil level
Lubrication with a grease gun Emptying the container
Lubricate with an oil can or spray can Replacing the contents of the
container
Table 5-1
Note
Established equivalent lubricants from other manufacturers can
also be used. SHELL Tellus Oil DO 46, MOBIL DTE 25, Fuchs
Renolin MR15, or CASTROL Hyspin DSP 46 are prescribed
explicitly for the hydraulic unit.
Lubrication point Quantity Recommended lubricant TRUMPF Mat. Identification Viscosity/

No. Consistency
Longitudinal and Klüber Microlube GL 261 1 kg: 106491 KP1N-30 NLGI 1
transverse guides
Transverse carrier Klüber Microlube GL 261 1 kg: 106491 KP1N-30 NLGI 1
and table support
bearings
Central lubrication 1 l OPTIMOL Optigear BM 460 4.5 kg: ISO VG 460
0347602
Hydraulic unit Max. SHELL Tellus Oil DO 46 1kg: 118445 HLPD ISO VG 46
230 l Fuchs Renolin MR15 182 kg: 035212
MOBIL DTE 25
CASTROL Hyspin DSP 46
Zero stop sensor SHELL Alvania RL2 K2K-30 NLGI 2
Punch spray 2.5 l TRUMPF punching and nibbling Aerosol can: ISO VG 150
lubrication, die oil SRH/5 chlorine-free (mild steel, 111309
spray lubrication stainless steel) 1 kg: 111310
10 kg: 111311
Wisura Akamin (aluminum and 20 l: 0061461

aluminum alloys)
B380EN05.DOC 3BLubrication 5-9

Lubrication point Quantity Recommended lubricant TRUMPF Mat. Identification Viscosity/
No. Consistency
Spray lubrication 2.5 l CASTROL Variocut B30 (mild 1 kg: 124302
tapping (optional) steel, stainless steel) 22 kg: 113149
CASTROL Variocut C462 1 l: 116941
(aluminum and aluminum alloys) 18 l: 116938
Die clamping Klüber Microlube GL 261 1 kg: 106491 KP1N-30 NLGI 1
piston clamp
Punch holder MICROGLEIT TN 3102 1 kg: 0355168

Rail transverse OPTIMOL Optigear BM 460 4.5 kg: ISO VG 460
carrier and table 0347602
support
Active die Cartridge Microlube GB 00 0111780
Table 5–3

3.2 Maintenance instructions
Longitudinal and transverse guides
(See Section 3.1, p. 5-8)
Lubricate grease nipple Maintenance interval: Every 2000 operating hours or at least once
a year.
The grease nipples on the longitudinal guide are arranged on two

plates, with nine nipples on each.
1 Grease nipple
Longitudinal guide Fig. 26852

All grease nipples on the bottom of the transverse guide must be
lubricated.
1 1
1 Grease nipples
Transverse guide Fig. 26914
1. Switch off the machine correctly, switch off the main switch,
lock it, and pull off the key.
2 Use grease gun to lubricate the grease nipple (1) on
longitudinal and transverse guides, until grease emerges.
Grease nozzle Fig. 38301

Transverse carrier and table support
bearings
(see section 3.1, p. 5-8)
Lubricate grease nipple Maintenance interval: every 2000 operating hours.
There are two grease nipples on each side.
1 1
1 Grease nipple
Fig. 26797
2. Use grease gun to lubricate grease nipple (1), until grease
emerges.
Grease nozzle Fig. 38301

Central lubrication
Check filling volume or refill Maintenance interval: Every 160 operating hours, at 1/3 of the
oil filling volume at the latest.
Note
The oil and air mixture is set at the factory.
Central lubrication container Fig. 26791
1. Shut down the machine properly, switch off the MAIN

SWITCH, lock it and pull out the key.
2. Consult the manufacturer regarding miscibility with other oils.
3. Check the filling volume of the oil, or refill oil.

Hydraulics
Check oil level Maintenance interval: every 40 operating hours.
1 Oil level indicator

Hydraulic oil tank Fig. 26799
¾ Check the oil level and ensure the oil is between the minimum
and maximum marks of the oil level indicator (1).
Analyze hydraulic oil For the first time after 5000 operating hours, at latest after 2 years.
Then every 2000 operating hours, at latest after 1 year.
Note
A service life of up to 5 years is possible for the oil if these intervals
are observed.
¾ Have the hydraulic oil examined by a lubricating agent

laboratory. Depending on the results, an oil change might have
to be carried out. The following analysis values are required:
– TAN (Total Acid Number).
– Viscosity
– Water content.

If the analysis results in at least one of the following values, then
the hydraulic oil must be changed:
• TAN (Total Acid Number) >2.5.
• Viscosity <41.4 mm2/s or >50.6 mm2/s for ISO VG 46.
• Water content > 500 ppm.
Value Explanation/effect
TAN (Total Acid Oil ages; surface corrosion and deposits possible.
Number)
Viscosity Significant deviations in viscosity are a sign of severe
contamination and foul oil.
Water content Water has a significantly higher vapor pressure than
oil. It can cause cavitation (low pressure can produce
vapor bubbles, that then implode suddenly (when
pressure is increased)). This causes erosion.
Table 5-4
If the water content is >1000 ppm, then damage to

components has probably already been caused!
Machine corrosion.
Warning ¾ Contact TRUMPF technical customer service.
Changing the hydraulic oil If the analysis of the hydraulic oil shows unacceptable values (see
above), at latest after 5 years.
There is a special connection for filling the hydraulic oil tank with
hydraulic oil on the return filter on the instrument plate of the
hydraulic unit.
An oil pump with hoses and connection fittings is delivered as part
of the accessories for the machine to enable the hydraulic oil to be
pumped from the oil drum into machine's hydraulic oil tank. This oil
pump is operated with a drilling machine.
Unfiltered oil can destroy the hydraulic system!

Guarantee claims rendered void!
¾ Use a filter with a fineness of at least 6 μm or a return filter
Caution (1.2) for filling.
¾ Make sure you leave the oil/air filter element and blue plastic
cap on the return filter when filling and in operation.
Note
Only use the same type of oil as before for topping up.

1 2 3
1 Black sealing screw with 2 Blue sealing cap

pressure switch 3 Return filter
Detail: hydraulic unit Fig. 26848

2. Fit the oil pump onto the holding sheet with two screws.
3. Attach the holding plate with oil pump e.g. onto the oil drum.

1
1 Filter insert
Return filter Fig. 26849
4. Undo the screws on the flange of the return filter and remove
the filter housing together with the filter insert (1).
5. Insert the oil hose with the suction piece into the hydraulic unit.
6. Hang the other end of the oil hose into the empty oil drum.
7. Install the drilling machine on the oil pump.
8. Pump the used oil into the oil drum.
9. Re-insert the filter housing together with the filter insert and
screw the flange tight.
10. Open the cover of the cleaning opening on the hydraulic unit,
remove the remaining oil sludge using a lint-free cloth and then
close the cleaning opening again (replace the seal if
necessary).
11. Remove the black sealing screw with the pressure switch. Do
not remove the blue sealing cap.

1 2
1 Adapter
2 Size-50 open-end wrench
12. Screw in the adapter (1) with the first coupling half on the
return filter and tighten it with a size-50 open-end wrench.
13. Lock the second coupling half into place.
14. Hang the oil hose with intake piece into the new oil drum.
15. Set the drilling machine to clockwise rotation.
16. Use the drilling machine to top up oil up to the maximum mark
on the level indicator without bubbles.
17. Unscrew the adapter on the return filter and remove the
fittings.
18. Replace the oil filter in the return filter.
19. Screw the black sealing screw with pressure switch back into
the return filter.
20. Switch on the machine and allow it to run for several minutes.
22. Check the oil level again and top up the oil if necessary.

Zero stop sensor (only TruPunch 5000 with
automation)
1 1
1 Grease nipple
Fig. 26818

2. Lubricate the grease nipples (1) using a grease gun.

Punch spray lubrication
Note
• Lubricants and cooling agents containing solvents, or agents
which attack the rubber seals and PVC lines are not suitable
for punch spray lubrication.
• For punch spray lubrication, it is also possible to use non-
aggressive synthetic lubricants and cooling agents with a
viscosity range of between ISOVG5 and ISOVG135 apart from
those oils named above.
Note
Do not allow the oil tank to run completely dry, since otherwise air
will enter the system!

2. Open the front hood.
3. Check the filling volume of the reservoir.

Refill oil Maintenance interval: If the level is less than ¼ of the filling
volume.
1 Filling nozzle 3 Quick-release coupling

2 Container
Fig. 26803

3. Undo the quick-release coupling (3) and pull out the reservoir
(2).
4. Open the filling nozzle (1).
5. Remove and clean the strainer basket.
6. Insert the strainer basket.
7. Pour in oil.
8. Close the filling nozzle.
9. Push in the container and lock the quick-release coupling into
place.
10. Close the front hood.
Note
The oil and air levels are preset by TRUMPF. It is possible to
adjust them.

Bleeding Maintenance interval: In case of drained container.
1 2 3
1 Adjusting screw 3 Bleed screw

2 Hose spiral
Detail: punching head Fig. 26792

2. Open the bleed screw (3).
3. Use the adjusting screw (1) to pump until air-free oil runs
through the hose coil (2).
4. Close the bleed screw.

Die spray lubrication (optional)
4
5
1 6
7
8 9
3
1 Quick oil filling 4 Reservoir pressure gauge 7 Manual operation unit

2 Fine oil adjustment 5 Fine air adjustment 8 Reservoir pressure adjustment
3 Level indicator 6 Oil filler plug (red) screw
9 Compressed air shut-off valve
Oil spray unit Fig. 37677
1. Switch off the machine correctly, switch off the MAIN SWITCH,
2. Check the filling volume of the container at level indicator (3).

Refill with oil At less than 1/4 of the filling volume
The reservoir pressure displayed on the pressure gauge (4)
drops back to "0".
2. Open the oil filler plug (6).
3. Use a funnel to fill the reservoir up to the maximum mark on
the level indicator (3) with oil.
4. Close the oil filler plug (6).
Note
The oil and air levels are preset by TRUMPF. It is possible to
adjust them.
Perfect operation is possible with the following basic settings in
combination with the recommended types of oil:
Adjusting screw Basic setting
Fine air adjustment (5) Turn the screw clockwise as far as it will go.
Then turn the screw in the other direction 8 full
turns.
Fine oil adjustment (2) Turn the screw clockwise as far as it will go.
Then turn the screw in the other direction 1 full
turn.
Table 5-5
Filling the supply line As needed.
The line must be filled if:

• The container is completely empty/has been emptied
completely, e.g. during the initial filling.
• The spraying results are not consistent.
1. Open the quick oil filler (1) by turning it approx. one turn
counterclockwise with an Allen key (Size 3).
2. Use a screwdriver to switch the manual operation unit (7) to
ON.
3. If an even stream of oil is emitted from the nozzle: turn the
manual operation unit (7) back to OFF.
4. Close the quick oil filler (1).

Tapping lubrication unit (optional)
Note
work.
Risk of injury when carrying out maintenance work when the

machine is switched on!
Danger indicate that maintenance work is being carried out or appoint
a supervisor.
the machine.
Check oil stream Maintenance interval: every 40 operating hours.
The oil must hit the thread former in a sharp, straight jet. After
several oil pulses, the oil must drip from the thread former. If this is
not the case, air has entered the system and oil cannot be
transported reliably.
Possible causes are:

• The oil reservoir is empty.
• The hose seal in the nozzle is defective.
Note
Do not allow the oil tank to run completely dry, since otherwise air
will enter the system!

3. Check the filling volume of the reservoir.

Bleeding The oil reservoir must be bled if it has been run empty by mistake
or another one is used.
1 2 3
1 Screw 3 Elbow union

2 Basic nozzle body
1. Turn key switch "Service mode" to the right and pull out key.
2. Open the hose fitting on the basic nozzle body (2). Do not
remove the hose.
3. Select "Operation - SET-UP - Switch elements."
4. Select the "General" switch element.
5. Select the "Lubricate tapping tool" switch element
approximately 10 times until no more bubbles are visible in the
hose.
6. Close the hose fitting.
7. Insert key and turn key switch "Service mode" to the left.

1
1 Reservoir
2 Quick-release coupling
Fig. 26804
Refill oil Maintenance interval: If the level is less than ¼ of the filling
volume.

3. Undo the quick-release coupling (2) and pull out the reservoir
(1).
4. Open the filling nozzle.
5. Remove and clean the strainer basket.
6. Insert the strainer basket.
7. Pour in oil.
8. Push in the container and lock the quick-release coupling into
place.
9. Bleed it if necessary.
10. Close the front hood.

Replace hose seal Maintenance interval: Every 500 operating hours and when
removing the nozzle.
The hose seal is a wearing part and must be replaced at the

specified intervals and each time the nozzle is replaced.
1 2 3
1 Screw 3 Elbow union

2 Nozzle

2. Undo the screw (1) and remove the basic nozzle body.
3. Unscrew the nozzle (2) from the basic nozzle body.
4. Pull the hose seal off the basic nozzle body.
5. The new hose seal must be pushed up to the collar on the
basic nozzle body and must close flush with the nozzle at the
front. The hose seal may have to be shortened.
6. Screw on the nozzle.

Die clamping piston clamp
Note
work.

a supervisor.
the machine.
1 Grease nipple
Detail: die holder Fig. 26800
1. Turn the C axis by 60°. To do so, select MDA mode and enter
the operating steps 1-2-3.
2. Enter the text, e.g.: C2=DC(60) F108000.
3. Lower the parts flap.

5. Lubricate the grease nipple (1) with a grease gun.
7. Turn the C-axis according to the instructions given above
by 300°.
9. Lubricate the second grease nipple.
Rail transverse carrier and table support
Clean and lubricate rail Maintenance interval: every 40 operating hours. More frequently if
sheets are heavily oxidized.

2. Clean the rail with a cleaning rag.
3. Lubricate the rail with an oily rag.

Punch holder
Lubricate punch holder Maintenance interval: every 500 operating hours.
1. Move the machine table in +Y direction.

2. Select "SET-UP activity – Rail assignment".
3. Press Change active tool.
4. Press Remove active tool.
5. Select "SETTING activity – Punching".
6. Press the "Tool clamp OPEN" switch element.
8. Use a greased brush to lubricate the punch holder on the
inside at the 20° angle in the area of the punch clamping.
Active die (optional)
Replacing a cartridge Maintenance interval: when indicated by the control system.
Note
The main switch on the switch cabinet can remain switched on.

1 Weight 3 Screw
2 Cartridge
Hydraulic unit: Cover removed Fig. 55148
1. Turn key switch FEED HOLD to the right and pull out the key.
2. To replace the cartridge:
– Remove the cover from the hydraulic unit.
– Turn the cartridge (2) 90° in counterclockwise direction and
remove it in upward direction.
– Remove the weight (1).
– Insert the new cartridge and lock it in clockwise direction.
– Put on the weight.
3. Remove the screw (3).
Note
One of the non-ventilated lubrication unit displays error
messages on the user interface.
4. Press the weight till the grease comes out at the screw.
The lubrication unit is ventilated.
5. Install the screw.
6. Install cover on the hydraulic unit.

4. Hydraulic system
4.1 Overview
1 5
2 3 3 4
1 Hydraulic accumulator 3 Hydraulic hoses 5 Hydraulic unit: oil filter

2 Stripper rod pressure diaphragm 4 Hydraulic unit: oil cooler
accumulator
Fig. 47755
5-34 4BHydraulic system B380EN05.DOC

4.2 Depressurizing the accumulator
system
Risk of injury from spurting fluids and gases expelled under

high pressure!
¾ The accumulator system must be depressurized for all work
Warning on the hydraulic system.
Note
Make absolutely sure the turning handles are closed again once
work on the hydraulic system is finished, since otherwise no
hydraulic pressure will be able to build up.
2
5
1 Hydraulic accumulator - low 4 High pressure turning handle

pressure 5 Pressure gauge - high pressure
2 Pressure gauge - low pressure 6 Hydraulic accumulator - high
3 Low pressure turning handle pressure
Fig. 26805
B380EN05.DOC 4BHydraulic system 5-35

2. Depressurize the high-pressure circuit by opening the turning
handle (4) and turning it until the pressure gauge (5) indicates
0 bar.
3. Depressurize the low-pressure circuit by opening the turning
handle (3) and turning it until the pressure gauge (2) indicates
0 bar.

Hydraulic accumulator
Four hydraulic accumulators are integrated in the hydraulic system.

The hydraulic accumulators are divided by an elastic partition
panel (membrane) into a gas chamber and a fluid chamber.
Note
Maintenance work on hydraulic accumulators may only be carried
out by persons who have been instructed accordingly. The
operating company is responsible for instructing personnel.
See also Pressure Vessel Code (for the Federal Republic of
Germany).
1 Sealing screw 4 Valve disk

2 Membrane 5 Fluid chamber (oil)
3 Gas chamber (nitrogen) 6 Steel tank
Fig. 2121
Note
The initial pressure in the gas chamber specified in the hydraulic
diagram is a prerequisite for the uninterrupted punching of
workpieces; regular inspections are essential.
The gas chamber may only be filled with nitrogen. The fluid
chamber stores hydraulic oil under pressure.
Check the hydraulic At regular intervals. According to §10 of the Pressure Vessel Code,
accumulator the interval and extent of the inspection should be determined by
the owner.

¾ Have the hydraulic accumulators checked at regular intervals
by qualified personnel in accordance with the German
Pressure Vessel Code. Outside Germany, the relevant national
provisions for checking hydraulic accumulators should be
observed.
Check the initial pressure of Maintenance interval: every 1000 operating hours.
the hydraulic accumulators
and refill them with nitrogen
if necessary
7
1
2
5
1 Hydraulic accumulator - low 5 Pressure gauge - high pressure

pressure 6 Hydraulic accumulator - high
2 Pressure gauge - low pressure pressure
3 Low pressure turning handle 7 Storage drain plug
4 High pressure turning handle
Fig. 26806

Risk of injury by explosion of the hydraulic accumulator!
¾ A pressure reducer with a pressure relief valve must be used
to fill each of the hydraulic accumulators 2.5, 2.23 and 2.24
Danger (see hydraulic plan).
¾ The pressure reducer must be set to the prescribed initial
pressure (see hydraulic plan).
¾ The stopcock on the nitrogen cylinder must be opened
carefully to allow the gas to escape slowly!
Define the initial pressure in 1. Open the punching head covering cap.
the low pressure hydraulic
accumulator 2. Switch on the hydraulic system.
The low pressure gauge must show approx. 70 bar.
3. Switch off the hydraulic system using E-STOP or MACHINE
ON/OFF.
4. Monitor the low pressure gauge (2.15).
The needle falls continuously (2-3 s) to a value (standard value 35
bar at 20°) and then suddenly drops sharply to 0 bar. The value
before the drop in pressure is equivalent to the initial pressure in
the low pressure hydraulic accumulator.
Define the initial pressure in 1. Open the punching head covering cap.
the high pressure hydraulic
accumulator 2. Switch on the hydraulic system.
The high pressure gauge must show approx. 260 bar.
3. Switch off the hydraulic system using E-STOP or MACHINE
ON/OFF.
4. Monitor the high pressure gauge (2.14).
The needle falls continuously (4-6 s) to a value (standard value
160 bar at 20°) and then suddenly drops sharply to 0 bar. The
value before the drop in pressure is equivalent to the initial
pressure in the high pressure hydraulic accumulator.
Note
The procedure is described in the separate manual supplied with
the filling and test device (mat. no. 346973).
Replace the stripper rod Maintenance interval: every 2000 operating hours.
pressure diaphragm
accumulator (see section 4.1, p. 5-34)

Risk of injury by explosion of the hydraulic accumulator!
¾ A pressure reducer with a pressure relief valve must be used
to fill each of the hydraulic accumulators 2.5, 2.23 and 2.24
Danger (see hydraulic plan).
¾ The pressure reducer must be set to the prescribed initial
pressure (see hydraulic plan).
¾ The stopcock on the nitrogen cylinder must be opened
carefully to allow the gas to escape slowly!
Two stripper rod pressure diaphragm accumulators are available

on the TruPunch 5000 (2.23 and 2.24), which must be exchanged.
1 Stripper rod pressure diaphragm

accumulator
Stripper rod pressure diaphragm accumulator Fig. 30921
Example 2.23

2. Depressurize the hydraulic system.
3. Unscrew the stripper rod pressure diaphragm accumulator
using an open-end wrench (size 30).
4. Screw the new stripper rod pressure diaphragm accumulator
tight with new Usit rings.
5. Charge the hydraulic system with pressure.

Hydraulics hose lines
Check the hydraulic hose Maintenance interval: Every 2000 operating hours, especially
lines clamp hose.
Risk of injury due to a bursting hydraulic hose flying around!

¾ Check all hydraulic hoses according to the maintenance
instructions.
Danger ¾ In case of a doubt, replace the hydraulic hose line.
Note
The hydraulic hoses should be checked by qualified personnel to
ensure safe operating standards. This check should also be carried
out before the first machine start-up.
Examples of possible defects to hydraulics hose lines:

• Damage to the outer layer extending up to the inner lining (e.g.
abrasions, cuts or tears).
• Brittleness of the outer layer (crack formation of the hose
material).
• Deformations which do not correspond to the natural form of
the hose in its pressurized or depressurized state or when
bent, e.g. separation of layers, bubble formation, crush areas,
kinks.
• Leaks
• The installation requirements were not met.
• Dislodging of the hose from the fitting.
• The fitting is damaged or deformed, which reduces the function
and tensile strength of the fitting or the connection between the
hose and fitting.
• Corrosion of the fittings; this results in impairing the
functionality and resistance of the fittings.
• The shelf life and period of use (according to ZH 1/74) have
been exceeded.

Note
• To avoid damage to the hydraulic hoses of the clamps, these
hoses must be inserted back into the transverse rail channel
after displacing the clamps.
• In addition to the above information, the relevant national
safety regulations and safety guidelines for hydraulic hoses
(order no. ZH 1/74) should be observed and maintained.
Issued by:
Employer's liability insurance association e. V.
PO Box 20 52
53757 St. Augustin, Germany
Sales:
Carl Heymanns Verlag KG
Luxemburger Str. 449
50939 Cologne

Hydraulic unit
Replace oil and air filters Maintenance interval: If displayed at the control panel or the
clogging indicator.
There is a red pushbutton on the contamination indicator. This red
pushbutton flips upwards if the oil filter is dirty, indicating that the
oil and air filters have to be replaced.
1 2 3
1 Black screw plug with clogging 2 Return filter

indicator 3 Blue cap
Fig. 38303

2. Open the blue cap (2) with a size 50 open-end wrench.

1
1 Oil filter 2 Air filter

Return filter Fig. 38304
3. Pull out the oil filter (1) (mat. no. 0349866) and replace it.
4. Replace air filter (2).
Note
There is a new oil and air filter at mat. no. 0349866.
5. Clean the filter lid with kerosene or benzine.

6. Check the seals and replace them if necessary
(mat. no. 0355031).
7. Close the blue cap tightly.
8. If the red pressure switch on the contamination indicator (1) is
turned upwards (switched position): press it back in.

Clean the oil cooler Maintenance interval: every 160 operating hours.
1 2 3
1 Filter mat 3 Cooling fins

2 Screw

2. Undo the screw (2).
3. Remove the filter mat (1) and clean it with a steam jet.
4. Insert the filter mat.
5. Vacuum-clean the cooling disks (3) with an industrial vacuum
cleaner. Remove any damp dirt deposits with a lint-free cloth.

5. Pneumatic system
5.1 Overview
1 Punch spray lubrication 2 Air cushions (optional)

Fig. 47756
5-46 5BPneumatic system B380EN05.DOC

Air cushions (optional)
Check air pressure Maintenance interval: every 500 operating hours.
1 2
1 Valve
2 Air cushion
Fig. 26794
1. Move the X axis to the center.

2. Approach the Y position Y1300 (TruPunch 5000, medium
format) or Y1600 (TruPunch 5000, large format).
SWITCH, lock it and remove the key.
4. Check the air pressure using an inflation measuring device
(mat. no. 079570) and refill with air if necessary.
Note
The pressure for TruPunch 5000 (medium format) must be 2.5–
3 bar and for TruPunch 5000 (large format) it must be 3–3.5 bar.
The optimal element height (air cushion lower edge – machine leg
lower edge) is 90 ± 2 mm.
5. Make sure the machine is level (spirit level).
B380EN05.DOC 5BPneumatic system 5-47

Punch spray lubrication
Set oil quantity Maintenance interval: as needed.
1st option:
Programming the spray tool lubrication in the NC text (see online
programming manual function "TC_TOOL_LUBE_ON)":
• TC_TOOL_LUBE_OFF: tool lubrication OFF.
• TC_TOOL_LUBE_ON(1): LOW tool lubrication: 1 dosing piston
stroke/s.
• TC_TOOL_LUBE_ON(2): AVERAGE tool lubrication: 1.5
dosing piston strokes/s.
• TC_TOOL_LUBE_ON(3): HIGH tool lubrication: 2 dosing
piston strokes/s.
• TC_TOOL_LUBE_ON(4): tool lubrication with each stroke, but
max. 3.3 dosing piston strokes/s.
2nd option:
Adjustment of the adjusting screw on the spray lubricator:
1 2 3
1 Adjusting screw 3 Bleed screw

2 Hose spiral
Fig. 26792
5-48 5BPneumatic system B380EN05.DOC

2. Set the oil quantity at the spray lubricator with the adjusting
screw (1). The adjusting screw clicks audibly into place four
times per revolution. If the oil is of very low viscosity, the oil
quantity must be set to 10 mm3/stroke.
Max. flow rate 30 mm3/metering piston stroke

1 complete turn to the left 25 mm3/metering piston stroke
2 complete turns to the left 20 mm3/metering piston stroke
3 complete turns to the left 15 mm3/metering piston stroke
4 full turns counter-clockwise 10 mm3/metering piston stroke
5 full turns in counterclockwise 5 mm3/dosing piston stroke
direction
More than 6 complete turns to the left 0 mm3/metering piston stroke
Table 5-6
3rd option:
Editing the tool technology table
1. Select the FOCUS menu.

2. Enter the operating sequence 1-1-5-8.
3. Enter 0, 1 or 4 in the "Tool lubrication" field.
0 No punch spray lubrication

1 Minimum punch spray lubrication
4 Maximum punch spray lubrication
Table 5-7
B380EN05.DOC 5BPneumatic system 5-49

6. Mechanical elements
6.1 Overview
1 2 3 4 5 6 7 8 9 10
11 2
1 Control panel 5 Punching tool adapter 9 Chip vacuum system: side

2 Racks and guide rails 6 Brush field segment tables, parts channel blower
3 Chip suction unit: suction tube flap, brush tables 10 Tool cartridge support slat
4 Air pressure maintenance unit 7 Stop pin 11 Chip suction unit: chip flap
8 Clamps
Fig. 47757
5-50 6BMechanical elements B380EN05.DOC

Punching tool adapter
Clean the punching tool Maintenance interval: every 8 operating hours.

adapter
1. Move the punching head into the highest position.

lock it, and remove the key.
3. Clean the upper and lower punching tool adapters and the
area around them with a cleaning rag or a brush.
B380EN05.DOC 6BMechanical elements 5-51

Chip vacuum system: side channel blower
Clean protective screen and Maintenance interval: every 2000 operating hours.
foam material filter
1 2
1 Hose to muffler
2 Hose to support bracket
Detail: side channel blower Fig. 26814

2. Undo the small flange.
3. Undo the connection hoses between the side channel blower
and support bracket (2) and between the side channel blower
and muffler (1).
4. Undo the four nuts on the foot of the side channel blower, turn
the side channel blower 180° and fasten it again with one nut.
5. Undo the large flange (six Allen screws).

2
1 Foam material filter

2 Protective screen
Detail: side channel blower Fig. 19484
6. Remove the protective screen (2) and the foam material filter
(1).
¾ Clean with them kerosene and purge them with
compressed air.
or
¾ Replace them if they are very dirty or damaged.
7. Install them in the reverse order.

Chip vacuum system: vacuum pipe
Clean strainer and filter Maintenance interval: every 40 operating hours. More frequently
when machining foil-coated sheets.
1 Connection hose
Detail: support bracket Fig. 26795

2. Remove the connection hose (1) from the console.

1 2 3
1 Filter 3 Strainer
2 Vacuum pipe
Fig. 26802
3. Remove the vacuum pipe (2).

4. Blow out the strainer (3) and the filter (1) (mat. no. 247122)
with compressed air.
5. Re-install the vacuum pipe and connection hose.
Chip vacuum system: chip flap
Note
• To ensure optimum chip suction, in particular when machining
thin sheets, make sure the chip flap is clean.
• The chip vacuum system must be switched off when working
with forming tools. Otherwise, the side channel blower could
overheat.

Clean the chip flap Maintenance interval: every 8 operating hours.

2. Remove the chips and wipe off any waste oil with a cleaning
rag.
Check sealing ring and Maintenance interval: every 40 operating hours.
replace if necessary
The sealing ring between the support bracket and chip flap is used
to seal off the closed chip flap to prevent outside air from entering.
1 Sealing ring
Chip flap Fig. 26807

2. Check the sealing ring (1) for cracks.
3. Replace the sealing ring if it is damaged (mat. no. 034874).

Chip vacuum system, complete
Check the low pressure of Maintenance interval: every 160 operating hours.
the chip vacuum system
Sufficient low pressure in the chip vacuum system is a prerequisite

for reliable vacuum disposal of chips and punching slugs.
Note
• The maintenance interval is shorter when machining foil-
coated sheets.
• The machine is switched on during the following maintenance
work.

a supervisor.
the machine.
1 2
1 Brush field 2 Screw

Segment tables Fig. 26812
The low pressure measuring device can be ordered from TRUMPF

(mat. no. 1236401).

1. Dismantle the back brush field (1) (size 10 Allen key).
2. Exit the danger zone and press the ACKNOWLEDGE LIGHT
BARRIER foot switch.
3. Clean vacuum pipe strainer/filter.
Note
The low pressure measurement only serves to find leakages.
It cannot be used to judge the status of the filter and the strainer.
Exception: filter and strainer are 100 % clogged up.
4. Set tool up with round die of 35 mm to 40 mm diameter at tool

station 1.
5. Use the TC_TOOL_STATION program to replace the tool at
the tool adapter.
6. Switch on the chip vacuum system.
– Select "Operation - SET-UP - MDA".
– Enter the command "TC_SUCTION_ON".
– Actuate the Start softkey.
7. Place low pressure measuring device on to die.
8. Leave the safety area holding the pressure gauge.
9. Activate the light barrier using the foot switch.
1 2 3 4
1 Pressure gauge 3 Die

2 Hose 4 Low pressure measuring device
Low pressure measuring device Fig. 33643

10. Read off pressure value (at least 200 mbar).
11. Switch off the chip vacuum system.
– Enter the command "TC_SUCTION_OFF."
– Actuate the Start softkey.
12. Remove low pressure measuring device.
13. Reassemble rear brush field.
14. Leave danger zone and press ACKNOWLEDGE LIGHT
BARRIER foot switch.
15. Press the ESTABLISH HOME POSITION button.
Perfect chip vacuum removal cannot be ensured if the required

pressure value is not reached. Reasons for this could be:
• The sealing ring between the support bracket and chip flap is
damaged.
• The support bracket is overfilled with chips.
• The side channel blower is blocked or defective.
• The ventilation valve is defective.
• The piping is leaking.
• The suction pipe strainer/filter is blocked.
Tool cartridge support slat
Clean support slat Maintenance interval: every 40 operating hours.

2. Clean support slat of the tool cartridge support slat with a
cleaning rag.

Clamps
Check cutting rings and Maintenance interval: Every 160 hours.

replace if necessary
Note
With sheet weights of ≥ 100 kg we recommend that cutting rings
are used.
1 Cutting rings
Fig. 26809

2. Check the cutting rings (1) for wear.
3. Replace worn out cutting rings (mat. no. 203177).

Racks and guide rails
Check and clean the racks Maintenance interval: every 40 operating hours.
and guide rails

2. Check the racks and guide rails - as far as they are visible and
accessible - for wear and damage, clean them with a brush
and kerosene and then lubricate them with Klüber Microlube
GB 00.
Index pin(s)
Clean the index pin(s) Maintenance interval: every 8 operating hours.

2. Clean the index pin(s) with a cleaning rag or brush.

Brush field segment tables, parts flap and
brush tables (optional)
Clean the brush field Maintenance interval: In case of great contamination.

segment tables, parts flap
and brush tables
Fig. 26815

2. Vacuum-clean the brush tables (optional) with an industrial
vacuum cleaner.
3. For cleaning, dismantle the brush fields as needed with a size
10 Allen key.
4. Remove the individual brush fields from the tool holder area as
needed, clean them in warm, soapy water and reinstall them.
5. Check the correct brush height with a ruler if necessary and
correct them as needed.
6. Clean the parts flap with a cleaning rag and brush.

Brush field segment tables
Set the height of the brush Maintenance interval: After the brushes have been used out.
fields
The front 5 brush fields in the die adapter area are height
adjustable. The brushes must be 0.3+0.2 mm over the working
height (die upper edge).

• Ruler
• Hexagon socket screw driver.
2 1 3 4
1 Brush field 1 3 Brush field 3

2 Brush field 2 4 Die holder
Fig. 32631


2. Remove the plastic caps on the screwed pins of the respective
brush field.
Brush field 1 and 2 are symmetrical to the die holders.
Brush field 1: every three screwed pins.
Brush field 2: every three screwed pins.
Brush field 3: every four screwed pins.
3. Every screwed pin is secured with a set screw. Turn out the set
screw by two turns within the screwed pins.
The set screw is wedge-shaped at its lower end and spreads
out the slotted screwed pin, which is secured in this way.
1 Brush insert 3 Set screw

2 Screwed pin 4 Base body
Screwed pin in the brush field Fig. 32636
4. Position the ruler onto the brush fields and the die, or to the left
and right of each ball roller on the tables.
5. Screw out the screwed pins evenly until the upper edge of the
brushes reaches the ruler.

6. Align the brush elements:
¾ For ball stages (standard), the brush fields of the segment
tables must be set at 0.3+0.2 mm higher then the ball rollers.
or
¾ For brush tables (optional), the brush fields of the segment
tables must be set at an equal height to the brushes on the
tables (0.5 mm higher than working height).
Damage of the segment tables!

¾ Do not secure the set screws and the screwed pin with
Loctite.
Caution
7. Tighten the set screws to secure the screwed pins.

8. Mount the plastic caps.

Compressed air maintenance unit
Check pressure and Maintenance interval: every 40 operating hours.

adjust if necessary
1 Pressure setting knob 3 Condensation water drain plug

2 Pressure gauge
Detail: instrument panel Fig. 26813

2. Check the pressure setting on the pressure gauge (2) (max. 6
+0.5 bar) and adjust the operating pressure on the pressure
adjustment knob (1) as required.

Switch off the machine Maintenance interval: every 500 operating hours.
The condensation is automatically drained when the machine is

switched off.
Replace filter cartridge Maintenance interval: every 2000 operating hours.

2. Shut off the compressed air supply.
3. Open the condensation water drain plug (3).
4. Open the 4 screws below and take off the base plate.
5. Unscrew the separating cap.
6. Replace the filter element if it is very dirty.
7. Install in the reverse order. Make sure that the sealing ring is in
the correct position.
Control panel
Check the filter mats for dirt Maintenance interval: as needed. The interval depends on the
and replace them if quality of the ambient air.
necessary
2. Dismantle the four louvered panels on the rear of the control
panel (two screws each).
3. If the mats are dirty, wash them with warm soapy water
(max. 60 °C) and hang them up to dry in a well-ventilated place
or replace them (mat. no. 149230).
4. Insert the upper filter mats with the more dense side facing
inwards and the lower filter mats with the more dense side
facing outwards.
5. Install the louvered panels.

7. Electrics
7.1 Overview
1 1 2
1 Sensor system - stripper sensor - Fan battery 3 Safety light barrier and light
2 Switch cabinet: - External air circuit barrier parts flap
- Connectors and clamping screw - Buffer battery
connections
Fig. 47758
B380EN05.DOC 7BElectrics 5-69

Switch cabinet: connectors and clamping

screw connections
Check the mounting devices Maintenance interval: every 2000 operating hours.
for the connectors and
clamping screw connections
Warning of electrical voltage.

¾ Work in the switch cabinet may only be carried out by
electricians or persons instructed in carrying out electrical
work.
Danger
¾ Unless specified otherwise, only carry out maintenance work
once the machine is switched off and de-energized.

2. Open the open switch cabinet.
3. Check the mounting devices for the connectors and clamping
screw connections for perfect working order.
4. Close the switch cabinet.
Switch cabinet: external air circuit
Clean external air circuit Maintenance interval: every 2000 operating hours.

work.
Danger

5-70 7BElectrics B380EN05.DOC

2. Clean switch cabinet from outside using compressed air.
Switch cabinet: NCU battery
Replace the NCK battery NC- Maintenance interval: every three years.
CPU (mat. no. 146881)

work.
Danger
Risk of injury if the battery contents come in contact with

skin or eyes.
¾ Do not charge the battery.
Warning ¾ Do not use force to open batteries.
¾ Do not throw batteries into fire.
¾ Dispose of the battery properly.
1 2
1 Latch
2 Battery location
Detail: switch cabinet Fig. 18077

3. Press the latch (1) up and pull out the fan forwards.
3 2
1 Battery 3 Battery plug

2 Holding latches
Fan Fig. 18076
4. Press the holding latches (2) outwards.

5. Pull out the battery plug (3).
6. Take out the battery (1).
7. Insert the new battery; observe the polarity while doing so.

Buffer battery box PC
Replace the buffer battery Maintenance interval: every five years.

(mat. no. 0364659)

work.
Danger

skin or eyes.
Warning of damaging components

¾ Replace lithium battery only with identical types or those
recommended by the manufacturer.
Caution

1
1 Buffer battery
2 PC box
Detail: switch cabinet Fig. 50250

3. Remove two screws on the upper housing cover and take it off.
4. Remove the plug of the buffer battery and cable ties.
5. Replace the buffer battery.

6. Fasten new buffer battery in its mounting device with a cable
tie.
7. Connect plug to the buffer battery.
8. Mount the housing cover.
9. Then set the configuration data again using the BIOS-SET-UP
program (see chapter 5 of the SIMATIC Box PC 620 manual).

Safety light barrier and light barrier parts
flap (optional)
Clean safety light barrier and Maintenance interval: every 500 operating hours.
light barrier parts flap
1 Light barrier parts flap

Fig. 26916

2 Clean the external lens surfaces with a clean, soft cloth or
cotton wadding. Cleaning agent: alcohol, 30 %.

Inductive proximity switch
Check the inductive Maintenance interval: At the time of replacement.

proximity switches
Note
The maintenance training course needs to be attended for the
following maintenance work.

2. Check the distance between the proximity switches and the
button.

Sensor system - stripper sensor
Clean sensor system - Maintenance interval: every 40 operating hours.

stripper sensor
1 Sensor
Fig. 26811

2
2 Reflector
Fig. 26917

2. Dismantle the cover on the upper left hand side of the machine
frame to gain access to the sensor.
3. Clean the sensor (1) and the reflector (2) with a clean, soft rag
or with cotton wool. Cleaning agent: alcohol, 30 %.
4. Install cover.
Set sensor system - stripper Maintenance interval: As needed when light barrier beam is
sensor with new device moved.

• Alignment device VR 15747 (mat. no. 1225409)
Note
work.

a supervisor.
the machine.
1. Dismantle the cover on the upper left hand side of the machine
frame to gain access to the sensor.
2. Move the Y axis forward until the first segment table is pressed
down.
1
3 4
1 Light barrier beam aligned to the 2 Marking 4 Die holder

marking 3 VR 15747 alignment device
Fig. 49112
3. When the tool clamp is open, insert alignment device

VR 15747 in the die holder.

4. Adjust the light barrier beam to the mark on the alignment
device:
– Loosen the screws on the sensor mounting device.
– Adjust the sensor until the light barrier beam hits the
marking on the alignment device.
– Tighten the screws on the sensor mounting device.
5. Install cover.

8. Cooling unit
Cooling water is needed for cooling the driver motors for the
coordinate guidance and to cool the machine body.
Cooling water additives have a caustic effect on skin and

eyes.
¾ Wear safety glasses and gloves.
Warning ¾ Observe instructions on product packaging.
Machine without Machine with an

an active die active die
Cooling water, Required 100 l 130
demineralized quantity (purge 50 l, (purge 65 l,
fill 50 l) fill 65 l)
Easy-Kit Drives
(mat. no. 0380437)
contains:
Aluminum inhibitor 2513 Corrosion protection Required 1 cylinder 1 cylinder
(4 3 ml cylinders) quantity per
water change
Biocide 2594 Protection against algae and 1 cylinder 1 cylinder
(4 3 ml cylinders) bacteria
Sanitzer ST40 Biocide for the cleaning cycle 1 cylinder 1 cylinder
(4 20 ml cylinders) with water changes
Table 5-8
Information on storage and • Demineralized water may only be stored for a short period of
handling time in order to avoid impairment of the water quality.
• The water must be transported in clean plastic containers.
• The specified chemical/physical characteristics must be
unconditionally observed. Consult your supplier with regards to
this matter.
• Avoid all unnecessary contact with the water (e.g. with hands).
Contact with foreign matter, except that specified by TRUMPF,
has a negative affect on the water quality.
• Additional equipment for filling water such as pumps, funnels,
hoses or stop cocks should be used exclusively for operation
with the cooling water.
– The pump is included in the scope of delivery of the
machine.
5-82 8BCooling unit B380EN05.DOC

• The demineralized water must undergo a simple inspection
regarding its color, cloudiness and odor before being used for
filling.
– Color/cloudiness: Any cloudiness (e.g. from suspended
matter, threads, flakes, particles) indicates water impurity.
In such cases, the system should not be filled with this
water.
– Odor: Any deviation from a neutral odor usually indicates
that the water is biologically contaminated. In such cases,
the system should not be filled with this water.
Check water level Maintenance interval: Every 160 hours.

2. Read off the water level on the water level indicator on the
cooling unit.
Top up with water Maintenance interval: as needed.

2. Top up with water according to the specification given above
and complement the additives in the correct proportion.
B380EN05.DOC 8BCooling unit 5-83

Replace water Every 6 months.
1 2
1 Drain cock 2 Filling cover

Example of Rittal cooling unit: Cover removed Fig. 26918
Removing used cooling water 1. Shut down the machine properly, switch off the MAIN
2. Suspend the holding sheet with a blue plate and an assembled
pump (included in the scope of delivery) for cooling water
replacement at the table support.
3. Remove the cover of the cooling unit.
4. Remove the sealing plug on the discharge flap (1) of the
cooling unit.
– Provide the reducing nipple 1/2-3/3" with a stopcock.
– Engage a hose.
– Connect the suction side of the pump to the hose.
Provide a container for the used cooling water.
5. Engage another hose on the pressure side of the pump and
connect it to the provided container.
6. Place the drilling machine on the pump and pump out the
cooling water.
– For complete emptying: tilt the cooling unit.
Clean the cooling circuit 7. Connect the pressure side of the pump to the drain cock of the
cooling unit.
8. Connect the suction side of the pump to the container for
demineralized water.

9. Fill the cooling unit with demineralized water till the upper edge
of the level indicator.
10. Remove the filling cover (2) and add 1 bottle of Sanitizer
ST 40.
11. Switch on the main switch and purge the cooling circuit for
30 min.
Switch off the machine in the correct way, switch off the MAIN
SWITCH, lock it, and remove the key.
12. Pump out water (see the previous steps).
Filling the cooling circuit, 13. Fill the cooling unit with demineralized water till the upper edge
adding additives of the level indicator.
14. Add one bottle each of Aluminium-Inhibitor 2513 and
Biocide 2594.
15. Close the filling cover.
16. Install cover.
17. Switch on the machine and operate the cooling unit for 5 min.
19. Check the water level at the level indicator and if required, fill
demineralized water till the maximum marking.
Check filter mats Maintenance interval: every 160 operating hours.

2. Remove the cover of the cooling unit (right).
3. Test the two filter mats (1) (upper and lower) for contamination.
4. Install the covers.
B380EN05.DOC 8BCooling unit 5-85

Replace filter mats Every 6 months, or when an error message appears on the
operating panel.
1 Filter mat (upper)

Fig. 26915

2. Remove the cover of the cooling unit (right).
3. Replace the two filter mats (1) (upper and lower) (mat. no.
0347570).
4. Install the covers.

9. Procedure after a collision
After a collision between a tool and workpiece, or with the die

adapter:

2. Die plate: check the wedge of the die plate and the groove of
the die adapter for damage.
3. Die adapter: if the die adapter is displaced by a collision, it
should be aligned according to the information sign attached
next to the die adapter.
Information plate Fig. 19477en
B380EN05.DOC 9BProcedure after a collision 5-87

10. Handling the setting device
10.1 Assigning the punch and alignment

ring
1 2 3 4 5
1 Allen key 4 Stop

2 Alignment ring 5 Bracket
3 Punch without alignment surface
Alignment of punch without alignment surface Fig. 21956
5-88 10BHandling the setting device B380EN05.DOC

6 7 4
4 Stop 7 Alignment surface

6 Punch with alignment edge
Alignment of punch with alignment surface Fig. 21955
1. Position the setting device upright.

2. Insert the punch with released alignment ring (2) in the tool
holder so that the wedge lies in the groove.
3. Fold up the bracket (5) and align the punch (3) to the stop (4):
bracket with two different indexed positions:
¾ Punch without alignment surface (stop is applied directly to
the straight punch geometry): pull the bracket into the
upper indexed position.
¾ Punch with alignment surface (6, 7): press the bracket into
the lower indexed position.
4. Fix the alignment ring in place with a size-5 Allen wrench (1).
B380EN05.DOC 10BHandling the setting device 5-89

10.2 Determining the tool length
Definition of the tool length: upper edge of the alignment ring to the
bottom edge of the punch (1).
1 2
1 Tool length
2 Dimension of the device
Fig. 21957
1. Lay down the setting device.

2. Measurement with digital slide caliper: zero the digital sliding
caliper by calibrating the dimension of the device (2) to 70 mm.
3. Measure the distance between the punch and setting device.
Deduct 70 mm (dimension of the device) from measurements
with the manual slide caliper.
4. Enter the measured value in the tool data of the machine
control system.
5-90 10BHandling the setting device B380EN05.DOC

11. Regrinding tools
The punch and die must be reground at the grinding face if there
are signs of wear (abrasion, damage to tool cutting edges). This is
particularly important for scratch-free machining.
Note
The procedure is described in the operating manual for the
QuickSharp.
The tools can be reground (while observing the clearance angle,

with punches) as follows:
Tool part Max. regrind length

New long punches 6.5 mm
Previous punches 3 mm
Angle-sheared punches (whisper 3 mm
tools)
MultiTool punch inserts 0.5 mm
Dies 1 mm
MultiTool die inserts or blanking die 1 mm
Table 5-9
B380EN05.DOC 11BRegrinding tools 5-91

11.1 Compensating the regrind amount
The ram stroke is increased or reduced (optimized stroke length)

depending on the regrind amount of the punch. For this purpose, it
is necessary to enter a tool length (in mm) in the tool data.
1 2
37.8 - 0.2 *
34.3 - 0.2
37.3 - 0.2
x1
x1
3 3
I : 18 - 0.1
x2
x2
II : 20 - 0.1
4 4
x2
x2
II : 20 - 0.1
*Long punch 4 Reinforced die

1 Flat punch x1 Regrind amount – punch
2 Whisper tool x2 Regrind amount
3 Standard die
Regrind amount Fig. 19525
5-92 11BRegrinding tools B380EN05.DOC

Flat tool Angle-sheared tool
-0.2
New punch: 34.3 mm New punch: 37.3-0.2 mm
(37.8-0.2 mm)
New standard die: New standard die:
Tool size I: 18-0.1 mm Tool size I: 18-0.1 mm
Tool size II: 20-0.1 mm Tool size II: 20-0.1 mm
New reinforced die: New reinforced die:

Tool size II: 20-0.1 mm Tool size II: 20-0.1 mm
Table 5-10
Note
• These dimensions are always the same for new tools which
have not been reground, irrespective of the tool geometry.
• Appropriate spacers are placed under reground dies.
• Make absolutely sure the correct tool length is entered in the
tool data, since collisions between the tool and workpiece
could otherwise occur when executing the program.
1 Tool length
Fig. 19528
Note
To ensure correct entries in the tool data, we recommend noting
down the tool length (upper edge of alignment ring to lower edge of
punch) on the magnetic disk (with new cartridges) or entering it into
the regrind length flag or noting it on the alignment ring with an oil
proof felt-tip pen (with old cartridges).
To ensure safe punching even with reground punches, the stripper

selection tables must be observed (see chapter "Description").
B380EN05.DOC 11BRegrinding tools 5-93

5-94 11BRegrinding tools B380EN05.DOC
Chapter 6
Maintenance of the
automation

2.1 SheetMaster and GripMaster maintenance
overview........................................................................... 6-8
2.5 Maintenance overview Double cart with guide rails....... 6-10
belt drive ........................................................................ 6-11
2.7 ShearMaster maintenance overview ............................. 6-11
3. Lubrication ................................................................... 6-13

3.2 Lubricant ........................................................................ 6-14

SheetMaster ............................................................. 6-16
SheetMaster ............................................................. 6-17
SheetMaster ............................................................. 6-18
SheetMaster ............................................................. 6-19
3.5 Lubricant ........................................................................ 6-25
Indexing .................................................................... 6-27
Rotary table .............................................................. 6-29
Drive motor gearbo................................................... 6-30
3.8 Lubricant ........................................................................ 6-32
3.11 Lubricant ........................................................................ 6-36
3.12 Maintenance instruction................................................. 6-36
Cam .......................................................................... 6-36
Flat gearbox.............................................................. 6-37
Screw joints .............................................................. 6-38
Weld joints ................................................................ 6-38
3.14 Lubricant ........................................................................ 6-40
Track rollers .............................................................. 6-40
Ball bearings ............................................................. 6-41
Flat gearbox.............................................................. 6-42

Screw joints .............................................................. 6-43
Weld joints ................................................................ 6-43
3.16 Lubrication chart for double cart with toothed belt
drive ............................................................................... 6-45
3.17 Lubricant ........................................................................ 6-46
Track rollers .............................................................. 6-46
Ball bearings ............................................................. 6-47
Flat gearbox.............................................................. 6-49
Screw joints .............................................................. 6-49
Weld joints ................................................................ 6-50
3.19 Lubricant ........................................................................ 6-51

scissor table................................................................... 6-59
4.2 Overview ........................................................................ 6-59

GripMaster ..................................................................... 6-65
5.2 Overview ........................................................................ 6-65
Scrap container......................................................... 6-71
Conveyor belt............................................................ 6-72



2.1 SheetMaster and GripMaster maintenance
overview........................................................................... 6-8
2.5 Maintenance overview Double cart with guide rails....... 6-10
belt drive ........................................................................ 6-11
2.7 ShearMaster maintenance overview ............................. 6-11
3. Lubrication ................................................................... 6-13

3.2 Lubricant ........................................................................ 6-14
SheetMaster ............................................................. 6-16
SheetMaster ............................................................. 6-17
SheetMaster ............................................................. 6-18
SheetMaster ............................................................. 6-19
3.5 Lubricant ........................................................................ 6-25
Indexing .................................................................... 6-27
Rotary table .............................................................. 6-29

Drive motor gearbox ................................................. 6-30
3.8 Lubricant ........................................................................ 6-32
3.11 Lubricant ........................................................................ 6-36
Cam .......................................................................... 6-36
Flat gearbox.............................................................. 6-37
Screw joints .............................................................. 6-38
Weld joints ................................................................ 6-38
3.14 Lubricant ........................................................................ 6-40
Track rollers .............................................................. 6-40
Ball bearings ............................................................. 6-41
Flat gearbox.............................................................. 6-42
Screw joints .............................................................. 6-43
Weld joints ................................................................ 6-43
3.16 Lubrication chart for double cart with toothed belt
drive ............................................................................... 6-45
3.17 Lubricant ........................................................................ 6-46
Track rollers .............................................................. 6-46
Ball bearings ............................................................. 6-47
Flat gearbox.............................................................. 6-49
Screw joints .............................................................. 6-49
Weld joints ................................................................ 6-50
3.19 Lubricant ........................................................................ 6-51

scissor table................................................................... 6-59
4.2 Overview ........................................................................ 6-59


GripMaster ..................................................................... 6-65
5.2 Overview ........................................................................ 6-65
Scrap container ....................................................... 6-71
Conveyor belt............................................................ 6-72


1. General guidelines
Appropriate maintenance is a prerequisite for maintaining the

quality of the machine. It prevents operational malfunctions and
their consequences. For this reason, please pay attention to the
following information.
Before putting the machine The machine must be lubricated carefully in accordance with the
into service lubrication chart before being put into service. The entire
lubrication of the machine has to be checked if the machine has
not been used for a long time (e.g. overseas transport). If required,
the gummy oil must be completely removed from all lubrication
points and supply lines.

¾ If not directly expressed otherwise, switch off the machine for
Danger maintenance work by the MAIN SWITCH, lock the switch and
removing the key.
¾ Strictly observe the safety regulations (see also the Safety
chapter) to avoid accidents.
Notes on cleaning The entire system should be cleaned at regular intervals. Coarse
elements of dirt and dust can be brushed off or vacuum-cleaned
using an industrial vacuum cleaner.
Notes on lubrication Refer to the lubrication chart and maintenance instructions for the
lubrication of the machine. The following points should also be
observed:
• Do not leave filler and drainage caps open for longer than
necessary and keep them clean at all times.
• Drain waste oil only at operating temperature.
• Do not use cleaning wool, kerosene, and benzole for cleaning
oil chambers. Only use non-fibrous cleaning cloths.
• Dispose of waste oil properly.
B380EN06.DOC 1BGeneral guidelines 6-7

2. Maintenance overview
2.1 SheetMaster and GripMaster

maintenance overview

(operating
hours)
8 Vacuum cups at SheetMaster Cleaning 67
160 X axis guide strip at the SheetMaster Clean and lubricate 15
160 Guide rails at the GripMaster Lubricate 22
160 Pivot bearings for grippers at the GripMaster Lubricate 23
160 Grippers at the GripMaster, movable parts Lubricate 23
160 Guide rods of the sheet thickness gauge at the Lubricate 19
SheetMaster
160 Stop pins on the movable GripMaster Lubricate 22
500 Pressure regulator on the SheetMaster Check 60
500 Pressure regulator on the SheetMaster Draining the condensation 60
water
500 Stripper unit (optional) guide rod on the SheetMaster Clean and lubricate 17
500 Pneumatic hoses at the scissor table Check 64
500 Light barriers at scissor table Cleaning 74
1000 Central lubrication on the SheetMaster Check filling volume and refill 20
with low-viscosity grease if
necessary
2000 X axis feedgear at the SheetMaster Check for leaks 21
2000 Z axis feedgear at the SheetMaster Check for leaks 21
2000 Y axis feedgear at the SheetMaster (optional) Check for leaks 21
2000 Cable tow chains on the SheetMaster Check 70
2000 Vacuum hoses Check 62
2000 Pneumatic bellows cylinder at the scissor table Check 64
2000 Safety device on the suction frame of the SheetMaster Lubricate 18
2000 Central lubrication on the SheetMaster Replace low-viscosity grease 20
2000 Pressure regulator on the SheetMaster Replace the filter element 61
Annually and Doweling of the SheetMaster, the GripMaster and the Check 66
whenever support table with the movable GripMaster with heavy-
necessary duty anchors
2 years TASC 100 control system battery Replace 73
As needed Vacuum cups at SheetMaster Replace 67
As needed Vacuum hoses on the SheetMaster Replace 62
As needed Filters in the suction cup vacuum connections Clean or replace 63
As needed X axis feedgear at the SheetMaster Refill oil 21
As needed Z axis feedgear at the SheetMaster Refill oil 21
As needed Y axis feedgear at the SheetMaster (optional) Refill oil 22

(operating
hours)
As needed Vacuum hoses in the suction frame of the SheetMaster Check vacuum 62
As needed Doweling on the SheetMaster Check in the event of 66
EMERGENCY STOP
Table 6-1
2.2 ToolMaster maintenance

overview (40/70)

(operating
hours)
500 rotary disk Lubricate 29
1000 Central lubrication Check filling volume and/ top up 29
oil if necessary
1000 Shifting unit (ToolMaster (70)) Lubricate 28
2000 Lifting device bearing Lubricate 26
2000 Indexing Lubricate 27
10000 Drive motor gearbox Oil change 30
Table 6-2
2.3 SortMaster Box maintenance overview

(operating
hours)
500 Rolling elements of the four-point bearing Lubricate 32
4 years Inner toothing of the slewing ring Oil change 34
Table 6-3
2.4 SortMaster Pallet maintenance

overview

(operating
hours)
160 Cam Check 36
500 Flat gearbox Check for leaks 37
1000 Roller chain and chain wheels Clean and lubricate 37

(operating
hours)
1000 Flange bearing unit Lubricate 37
2000 Screw joints Check 38
2000 Weld seams Check 38
10000 or 4 Flat gearbox Oil change 37
years
As needed Cam Replace 36
As needed Weld seams Renew 38
As needed Screw joints Replace 38
Table 6-4
2.5 Maintenance overview

Double cart with guide rails

(operating
hours)
160 Track rollers Check 40
160 Ball bearings Check 41
years
As needed Track rollers Replace 40
As needed Chain tension Fine tune 42
As needed Ball bearings Replace 41
Table 6-5

2.6 Maintenance overview for double cart
with toothed belt drive

(operating
hours)
8 Running surfaces Cleaning 46
160 Track rollers Check 46
160 Ball bearings Check 47
years
As needed Track rollers Replace 47
As needed Chain tension Fine tune 48
As needed Ball bearings Replace 47
Table 6-6
2.7 ShearMaster maintenance overview

(operating
hours)
160 Scrap container Check the cut quality of the scrap 71
500 Conveyor belt on the ShearMaster Lubricate cable on the conveyor belt 52
500 Conveyor belt on the ShearMaster Check for damage 72
Check cable tension
1500 Presser foot on the scissor unit on the Lubricate 53
ShearMaster
1500 Blade slide on the ShearMaster Lubricate 57
2000 Hydraulics on the ShearMaster Analyze hydraulic oil 53
5000 Hydraulics on the ShearMaster Change hydraulic oil 53
Table 6-7

For single-shift operation:
eight operating hours Daily

40 operating hours Weekly
160 operating hours Every month
500 operating hours Every three months
1000 operating hours Every 6 months
2000 operating hours Once a year
5000 operating hours After 2½ years
10000 operating hours After 5 years
Every 2/4/5 years After every 2/4/5 years, regardless of the
number of operating hours
Table 6-8

3. Lubrication
3.1 Lubrication chart for SheetMaster with

GripMaster
2000
h
1000
500
160
1 2 3 4 5 6 7 8 9 10 11 12
1 X axis guide strip 10 Guide rails at the GripMaster Lubricate with an oil can or
2 Support columns on the carrier 11 Stop pins on the movable spray can
suction cup GripMaster Monitor oil level and, if
3 Stripper unit (optional) guide rod 12 Grippers on GripMaster
necessary, top up to
4 Suction frame safety device required level
5 Sheet thickness gauge Checking the oil level
6 Central lubrication
7 Z axis feed gear Indication of lubrication Emptying the container
8 X axis feed gear h intervals in operating hours
9 Y axis feed gear (optional) Read the maintenance Replacing the contents of
instructions the container
Lubrication with a grease
gun
Fig. 38300

3.2 Lubricant
Note
also be used.
Lubrication point Quantity Recommended lubricant Identification Viscosity

Pick-up columns of the carrier cups at ARAL Aralub HLP 2 KP2 K NLGI 2
the SheetMaster BP Energrease LS-EP 2
X axis guide strip at the SheetMaster SHELL Alvania EP grease 2
Safety device of the suction frame at MOBIL Mobilux EP 2
the SheetMaster ELF Epexa 2
Guide rails at the GripMaster ESSO Beacon EP 2
FUCHS Renolit FEP 2
Pivot bearings for grippers at the BP Energol GR-XP 220 CLP 220 ISO VG 220
GripMaster ESSO Spartan EP 220 CLP 220
Grippers at the GripMaster, movable ESSO Febis K 220 CGLP 220
parts MOBIL Mobilgear 630 CLP 220
Guide rods of the sheet thickness MOBIL Vactra Oil No 4 CGLP 220
gauge at the SheetMaster SHELL Omala oil 220 CLP 220
Stripper unit (optional) rod on the SHELL Tonna oil T 220 CGLP 220
SheetMaster ARAL Degol BG 220 CLP 220
Stop pins on the movable GripMaster ARAL Deganit B 220 CGLP 220
BP Maccurat 220 D CGLP 220
CASTROL Alpha SP 220 CLP 220
CASTROL Magna CHT 220 CGLP 220
ELF Moglia 220 CGLP 220
ELF Reductelf SP 220 CLP 22
FUCHS Renep CLP 220
Compound 106 CGLP 220
FUCHS Renep 220 K
X axis feedgear at the SheetMaster 1l FUCHS Renolin PG 220 PG 220 ISO VG 220
Z axis feedgear at the SheetMaster
Y axis feedgear at the SheetMaster
(optional)
Central lubrication on the KLÜBER Microlube GB 00 GB 00 NLGI 00
SheetMaster
Safety device of the suction frame at 2.5 l Gleitmo
the SheetMaster
Table 6–9

X axis guide strip at the SheetMaster
Clean and lubricate the X axis Every 160 operating hours.

guide strip
2. Clean the guide strip using kerosene and a brush.
3. Lubricate the cleaned areas.

SheetMaster
Lubricate the pick-up Every 2000 operating hours.

columns
5
4
3 6
8
2
1 Vacuum cup 5 Bearing bushing

2 Nipple 6 Fixing nut
3 Compression spring 7 Pneumatic connection
4 Supporting pin 8 Filter
Example: Carrier cup design (∅ 45 mm) Fig. 27650

2. Push up the suction cup as far as it will go.
3. Grease the pick-up column slightly.
4. Check the edge of the vacuum sealing lip.

SheetMaster
Cleaning and lubricating the Every 500 operating hours.

stripper unit guide rod
1 Guide rod
Fig. 27665

2. Clean the guide rod using kerosene and a brush.
3. Lubricate the cleaned areas with an oilcan.

SheetMaster
Lubricate the support areas Every 2000 operating hours.

of the pins
1
1 Support area of the pins

Design of the safety device Fig. 18092
Note
The suction frame must be raised to allow the support areas of the
pins to be lubricated.

2. Lubricate the support areas of the pins.

Guide rods of the sheet thickness gauge at
the SheetMaster
Lubricate the guide rods of Every 160 operating hours.

the sheet thickness gauge
1 Guide rods
Fig. 27678

2. Lubricate the guide rods by means of an oil can.

Central lubrication on the SheetMaster
Check filling volume and refill Every 1000 operating hours, but at the latest when down to 1/3 of
with low-viscosity grease if the filling volume.
necessary
Note
The amount of low-viscosity grease apportioned is set at the
factory.
1 Central lubrication
Fig. 27656

2. Check the filling volume of the low-viscosity grease and top up
the low-viscosity grease if necessary.
Replace low-viscosity grease Every 2000 operating hours.

2. Remove the low-viscosity grease from the container.
3. Refill the container.

X axis feedgear at the SheetMaster
Check the gearbox for leaks Every 2000 operating hours.
Note
The gearbox is filled with synthetic oil at the factory and is
maintenance-free under normal operating conditions.
Refill with oil As needed.

2. Refill with oil.
Z axis feedgear at the SheetMaster
Note
The gearbox is filled with a synthetic oil at the factory, and is
Refill oil As needed.

2. Refill with oil.
Y axis feedgear at the SheetMaster

(optional)

Note
The gearbox is filled with a synthetic oil at the factory, and is
Refill oil As needed.

2. Refill with oil.
Guide rails at the GripMaster
Lubricate grease nipple Every 160 operating hours.

2. Lubricate the grease nipples using a grease gun.
Stop pins on the movable GripMaster
Lubricate stop pins Every 160 operating hours.

2. Remove 4 screws on the cover.
3. Lift cover.
4. Lubricate stop pins with the oilcan.

Grippers on the GripMaster
Lubricate the pivot bearing Every 160 operating hours.

and movable parts
Risk of crushing during maintenance work on the grippers!
¾ Select SET-UP Operation – Switch elements – "GripMaster"

Danger – "Gripper" switch element to depressurize the grippers.
1 Grippers
Fig. 27657

2. Lubricate the pivot bearing and movable parts using an oil can.

3.4 Lubrication chart for
ToolMaster (40/70)
10000
h
2000
1000
500
1 2 3 4 5 6
c Lifting device bearing h

Indication of lubrication Monitor oil level and, if
d Indexing
intervals in operating hours necessary, top up to
required level
eShifting unit (ToolMaster (70)) Read the maintenance Checking the oil level
f Rotary table instructions
g Central lubrication Lubrication with a grease Emptying the container
h Drive motor gearbox gun
Lubricate with an oil can or Replacing the contents of

spray can the container
Fig. 27664

3.5 Lubricant
Note
also be used.
Lubrication point Quan- Recommended lubricant Mat.- no. Identifi- Viscosity

tity cation
Central lubrication 0.25 l KLÜBER Microlube GB 00 0111780 GP-10 NLGI 00
rotary disk ARAL Aralub HLP 2 KP 2K NLGI 2
Lifting device BP Energrease LS-EP 2
bearing SHELL Alvania EP grease 2
Indexing MOBIL Mobilux EP 2
Shifting unit ELF Epex ELF 2
(ToolMaster (70)) ESSO Beacon EP 2
DEA Glissando EP 2
KLÜBER Centoplex GLP 402
Drive motor 0.75 l CASTROL Alphasyn T68 PG 68 ISO VG 68
gearbox ELF Syntherma P 55
FUCHS Renodiol PGP 68
KLÜBER Syntheso HAT 68
Table 6-10

Lifting device bearing
1 Lifting device cover

Fig. 27653

2. Lubricate the four grease nipples using a grease gun.

Indexing
Lubricate the indexing Every 2000 operating hours.
1 2 3
1 Pneumatic cylinder 3 Indexing

2 Piston
Indexing Fig. 9993

2. Lubricate the indexing using a grease gun.

Shifting unit (ToolMaster (70))
1 Grease nipple
Fig. 27673

2. Lubricate four grease nipples using a grease gun.

Rotary table
1 2
1 Grease nipple 2 Rotary table

Fig. 27654

2. Lubricate four grease nipples using a grease gun.
Central lubrication
Check filling volume and refill Every 1000 operating hours, but at the latest when down to 1/3 of
with low-viscosity grease if the filling volume.
necessary
Note
The grease and air mixture is set at the factory.

2. Check the filling volume of the low-viscosity grease and top up
low-viscosity grease if necessary.

Drive motor gearbox
Change oil Every 10.000 operating hours.
1 Gearbox
Fig. 27672

2. Change the oil.

3.7 Lubrication chart for SortMaster Box
4 Jahre
h
500
1 2
c Rolling elements of the four-point h

bearing
d Inner toothing of the slewing ring

required level
Read the maintenance Checking the oil level
instructions
Lubrication with a grease Emptying the container

gun

Fig. 27674

3.8 Lubricant
Note
also be used.

tity cation
Rolling bearings ARAL Aralub HLP 2 KP 2K NLGI 2
of four-point BP Energrease LS-EP 2
bearing SHELL Alvania EP grease 2
MOBIL Mobilux EP 2
ELF Epex ELF 2
ESSO Beacon EP 2
DEA Glissando EP 2
KLÜBER Centoplex GLP 402
Inner toothing of 2l KLÜBER Microlube GB 00 0111780 GP-10 NLGI 00
slewing ring
Table 6-11
Rolling elements of the four-point bearing

a supervisor.
the machine.
Note
The parts container and motor cover must be removed.

1
1 Grease nipple
Fig. 27675
1. Select SET-UP Operation – "SortMaster" switch element.

2. Press the "SortMaster jog mode" switch element until both
grease nipples are accessible.
3. Lubricate the grease nipple using a grease gun.
4. Move the SortMaster Box manually onto a 90° angle.

Inner toothing of slewing ring
Replace low-viscosity grease Every 4 years.
1 Inner toothing
Fig. 27676
2. Take out the container.
3. Remove the motor shell.
4. Dismantle the motor with rotary drive.
5. Remove low-viscosity grease.
6. Mount and fit the motor with rotary drive.
7. Pour in low-viscosity grease.

3.10 Lubrication chart for SortMaster Pallet
h 10000
(max. 4 Jahre/
years/années)
1000
3 2 1 3
c Flat gearbox h
d Flange bearing unit

required level
eRoller chain and chain wheels Read the maintenance Checking the oil level
instructions

gun

Fig. 28383

3.11 Lubricant
Note
also be used.

tity cation
Flat gearbox 0.7 l BP Energol GR-XP 220 CLP 220 ISO VG 220
ESSO Spartana EP 220 CLP 220
SHELL Omala oil 220 CLP 220
ARAL Degol BG 220 CLP 220
Flange bearing SKF grease LGMT 2 K2K NLGI 2
unit
Roller chains, REXNORD chain spray Rexoil ISO VG 30-100
chain wheels Klüber Structovis FHD (SAE 20-40)
Table 6–12
Cam
(see section 0, p. 6-35)
Check the cam Every 160 operating hours

2. Open the chain lock.
3. Check the cam.
4. Close the chain lock.
Replace the cam As needed.

2. Open the chain lock.
3. Remove the defective cam.
4. Install a new cam.
5. Close the chain lock.

Flange bearing unit
Lubricate the flange bearing Every 1000 operating hours.

unit
2. Lubricate the grease nipples using a grease gun.
Roller chains and chain wheels
Clean and lubricate the roller Every 1000 operating hours.

chains and chain wheels
2. Clean the roller chains and chain wheels with a brush.
3. Lubricate the roller chains and chain wheels using an oil can.
Flat gearbox
Check the flat gearbox for Every 500 operating hours.

leaks
2. Open the bleed screw.
3. Clean the bleed screw if necessary.
4. Check the gearbox for leaks by means of a visual inspection.
Oil change Every 10000 operating hours or after 4 years at the latest.
Note
Drain the waste oil at operating temperature.


2. Remove the bleed screw.
3. Place a suitable container under the oil drain plug.
4. Remove the oil drain plug.
5. Purge with oil of the same viscosity.
6. Close the oil drain plug.
7. Fill with 0.7 l oil.
8. Install the bleed screw.
Screw joints
Check the screw joints Every 2000 operating hours.

2. Check the screw joints for damage.
Replace the screw joints As needed.

2. Replace the screw joints.
Weld joints
Check the weld joints Every 2000 operating hours.

2. Check the weld joints for cracks.
Renew the weld joints As needed.

2. Renew the weld joints properly.

3.13 Lubrication chart for double unloading
cart
h 10000
(max. 4 Jahre/
years/années)
1000
1 2 3 2
c Flat gearbox h

required level
eRoller chain and chain wheels Read the maintenance Checking the oil level
instructions

gun

Example: Double unloading cart Fig. 28381

3.14 Lubricant
Note
also be used.

tity cation
unit
Table 6-13
Track rollers
Check the track rollers Every 160 operating hours.

2. Check the track rollers.
Replace the track rollers As needed.

2. Remove the retaining rings.
3. Remove the axis or spindle.
4. Remove the defective track roller.
5. Insert a new track roller.
6. Install the axis or shaft and secure it with retaining rings.
7. Install the retaining rings.

Ball bearings
Check the ball bearings Every 160 operating hours.

2. Check the ball bearings.
Replace the ball bearings As needed.

4. Remove the defective ball bearing.
5. Insert a new ball bearing.
Flange bearing unit

unit
2. Remove the safety covers on the drive side of the upper
carriage.
4. Install the protective covers.


2. Remove the protective covers from the upper carriage frame.
5. Install protective covers on the upper carriage frame.
Readjusting the chain As needed.

tension
Note
The chain tension must be fine tuned if, during positioning, the
upper carriage shows signs of unevenness, e.g. jerky movements.

2. Undo the fixing screws of the flange bearing unit.
3. Set the vertical bearing adjusting screw so that chain can be
deflected by hand within the vertical installation opening no
more than ≤5 mm.
Flat gearbox

leaks

Oil change Every 10000 operating hours or after 4 years at the latest.
Note

6. Fit the oil drain plug.
Screw joints


Weld joints




3.16 Lubrication chart for double cart with
toothed belt drive
10000
h
1000
3 1 2 2 1 3
c Flat gearbox h

required level
eRoller chain Read the maintenance Checking the oil level
instructions

gun

Fig. 39235

3.17 Lubricant
Note
also be used.

tity cation
unit
Table 6-14
Running surfaces
Clean running surfaces Every 8 operating hours.

2. Clean the running surfaces.
Track rollers
Check the track rollers Every 1000 operating hours.

2. Check the track rollers.

Replace the track rollers As needed.

4. Remove the defective track roller.
5. Insert a new track roller.
Ball bearings
Check the ball bearings Every 1000 operating hours.

2. Check the ball bearings.
Replace the ball bearings As needed.

4. Remove the defective ball bearing.
5. Insert new ball bearing.

Flange bearing unit

unit
2. Remove the safety covers on the drive side of the upper
carriage.
4. Install the protective covers.

2. Dismantle safety covers on the upper carriage frame.
5. Install protective covers on the upper carriage frame.
Readjust the chain tension As needed.
Note
The chain tension must be fine tuned if, during positioning, the
upper carriage shows signs of unevenness, e.g. jerky movements.

2. Undo the fixing screws of the flange bearing unit.
3. Set the vertical bearing adjusting screw so that chain can be
deflected by hand within the vertical installation opening no
more than ≤5 mm.

Flat gearbox

leaks
Change oil Every 10000 operating hours or after 4 years at the latest.
Note

6. Fit the oil drain plug.
Screw joints



Weld joints



3.18 Lubrication chart for ShearMaster
5y
h 1500
500
1 4 2 3
1 Conveyor belt 3 Blade slide

2 Presser foot on the scissor unit 4 Hydraulic system
Lubrication chart Fig. 47950
Maintenance interval in Read operating manual

operating hours
Lubrication by means of Lubricate with an oil can

grease-/oil-press or spray can
Table 6-15
3.19 Lubricant
Lubrication point Quantity Recommended lubricant TRUMPF Identifi- Viscosity

mat. no. cation
Hydraulic unit 160 l SHELL Tellus Oil DO 46 1 kg: 118445 HLPD ISO VG 46
Fuchs Renolin MR15 182kg:
MOBIL DTE 25 035212
CASTROL Hyspin DSP 46
Presser foot on the scissor Max. 5 g per Klüber Microlube GL 261 0106461 KP1N-30 NLGI 1
unit on the ShearMaster lubrication
point
Blade slide at ShearMaster Max. 10 g per Klüber Microlube GL 261 0106461 KP1N-30 NLGI 1
lubrication
point
Lubricants Table 6-16

Conveyor belt on the ShearMaster

(see section 2.7)
Lubricate cable on the Every 500 operating hours.

conveyor belt
1
1
1
1 Cable on the conveyor belt

Fig. 47947
1. Switch to SETUP.
2. Select switch element group ShearMaster.
3. Manually start ShearMaster.
– Select 2.Start and press TOGGLE.
4. Manually stop ShearMaster when the conveyor belt has moved
up to the scissor unit.
– Press RESET .
6. Lubricate cable with an oil-soaked cloth.

Hydraulics on the ShearMaster
(see section 2.7)
Analyze hydraulic oil For the first time after 5000 operating hours, at latest after 2 years.
Then every 2000 operating hours, at latest after 1 year.
Note
A service life of up to 5 years is possible for the oil if these intervals
are observed.
¾ Have the hydraulic oil examined by a lubricating agent

laboratory. Depending on the results, an oil change might have
to be carried out. The following analysis values are required:
– TAN (Total Acid Number).
– Viscosity
– Water content.
If the analysis results in at least one of the following values, then

the hydraulic oil must be changed:
• TAN (Total Acid Number) >2.5.
• Viscosity <41.4 mm2/s or >50.6 mm2/s for ISO VG 46.
• Water content > 500 ppm.
Value Explanation/effect
TAN (Total Acid Oil ages; surface corrosion and deposits possible.
Number)
Viscosity Significant deviations in viscosity are a sign of severe
contamination and foul oil.
Water content Water has a significantly higher vapor pressure than
oil.
It can cause cavitation (low pressure can produce
vapor bubbles, that then implode suddenly (when
pressure is increased)). This causes erosion.
Table 6-17
If the water content is >1000 ppm, then damage to

components has probably already been caused!
Machine corrosion.
Warning ¾ Contact TRUMPF technical customer service.
Change hydraulic oil If the analysis of the hydraulic oil shows unacceptable values (see
above), at latest after 5 years.
1. Completely loosen the belt tension of the left conveyor belt in

home position.

1
1 Conveyor belt 3 Connection pin

2 Mandrel
Fig. 50581
2. Open left conveyor belt on the front of the table. To do this, lift
the conveyor belt, use a mandrel to push the connection pin a
bit from where it is fastened and then pull it out.

1
1 Tank opening
Fig. 50580
3. Roll the conveyor belt back and forth. Remove the holder of
the temperature sensor or dummy cover that becomes free. In
machines without a temperature sensor or dummy cover, also
open the right conveyor belt, unscrew the tank cover, and
move it.
4. Pump out waste oil through the opening that becomes free and
fill with new oil.
5. Close cover and install conveyor belt. Reestablish belt tension.

Presser foot on the scissor unit on the ShearMaster
(see section 2.7)
Lubricate Every 1500 operating hours.
1
1
1 Grease nipple on the presser

foot
Fig. 47946
2 Lubricate the grease nipples using a grease gun.

Blade slide on the ShearMaster
(see section 2.7)
Lubricate Every 1500 operating hours.

Risk of injury
¾ Wear gloves.
Warning
The blades' cutting edges are sharp.

Risk of injury
¾ Wear gloves.
Warning
1 Blade slide grease nipple

Fig. 47949
1. Switch to SETUP.
3. Select 3.Jogging.
4. Move the blade with + down.

1
1 Blade slide grease nipple (left)

Fig. 47948
6. Remove the scrap container.
7. Lubricate the lubricating heads using a grease gun.

4. Pneumatic components
4.1 Pneumatic components on the

SheetMaster and scissor table
4.2 Overview
1 2 3 4 5
1 Pressure regulator 3 Filter in suction cup vacuum 5 Pneumatic hoses on scissor

2 Vacuum hoses in suction frame connections table
4 Pneumatic bellows cylinder on
scissor table
Fig. 27660
B380EN06.DOC 4BPneumatic components 6-59

Pressure regulator
Check the pressure regulator Every 500 operating hours.
1 2 3 4 5
1 Manual shut-off valve 4 Pressure gauge

2 Sight glass 5 Condensation drain plug
3 Pressure regulator
Fig. 31592

2. Check the pressure regulator for an operating pressure of 6.5
bar.
Drain the condensation water Every 500 operating hours.

2. Turn condensation drain plug to the left.
3. Turn condensation drain plug to the initial position.
6-60 4BPneumatic components B380EN06.DOC

Replace filter element Every 2000 operating hours.

2. Shut off the compressed air supply.
3. Open the condensation water drain plug.
4. Open the 4 screws below and take off the base plate.
5. Unscrew the separating cap.
6. Replace the filter element if it is very dirty.
7. Install in the reverse order. Make sure that the sealing ring is in
the correct position.

Vacuum hoses in the suction frame
Check the vacuum hoses Every 2000 operating hours.
Check the vacuum of the As needed.

suction cups

a supervisor.
the machine.
1. Lower the suction frame onto the unprocessed sheet stack so

that all suction cups are covered.
2. Select SET-UP Operation – Switch elements - "SheetMaster"
switch element.
3. Select the "Suction cup leak test" switch element.
4. Select the "Vacuum ON" switch element.
5. Check all suction cups using the jog keys.
If a suction cup is leaking, the vacuum switch will frequently switch

on.
In this case:
¾ Check the vacuum cups and filters in the vacuum
connection
or
¾ Replace the vacuum hoses.

Filters in the suction cup vacuum
connections
Clean the filters in the As needed.

suction cup vacuum
connections If there is a delay in the separation of the sheet from the suction
cups during aeration, the filters in the vacuum connections are
dirty. The filters become dirty more quickly when machining highly
oxidized sheets.

a supervisor.
the machine.
1. Select SET-UP Operation – Switch elements - "SheetMaster"

switch element.
2. Select the "Clean suction cup" switch element.
The suction cup cleaning cycle is carried out.
If the cleaning cycle is not sufficient:

3. Pull off the hose.
4. Clean the filter with compressed air.
or
¾ Replace the filter.

Pneumatic bellows cylinder at the scissor
table
Check the bellows cylinder Every 2000 operating hours.
1 Bellows cylinder
Fig. 27662
Pneumatic hoses at the scissor table
Check the vacuum hoses Every 500 operating hours.

5. Mechanical components
5.1 Mechanical components at the

SheetMaster and GripMaster
5.2 Overview
1 2 3 3 3 1
1 Doweling of the SheetMaster and 2 Vacuum cups 3 Cable tow chains

GripMaster with heavy-duty
anchors
Fig. 27659
B380EN06.DOC 5BMechanical components 6-65


support table with movable GripMaster
SheetMaster GripMaster Support table with

GripMaster
Heavy-duty anchors HSL-G-TZ M16 HSL-TZ M12/25 FH12/50H 45059
Rated torque with torque wrench 120 ±10 Nm 80 ±10 Nm 25 ±10 Nm
Table 6-18
Check the doweled joints Annually.

2. Check the rated torques.
Checking the doweling in As needed.

case of EMERGENCY STOP
If the SheetMaster has been moved to the fixed stop in the event of
EMERGENCY STOP:
2. Check the fixed stop.
3. If necessary, set the fixed stop to the required position and
replace the fixing screws.
4. Check the foundation for cracks and bumps.
5. Check the heavy-duty anchors.
6-66 5BMechanical components B380EN06.DOC

Vacuum cups on the SheetMaster
Clean the vacuum cups Every 8 operating hours, or even more frequently when machining
highly oxidized sheets.
1. Switch off the machine properly, switch off the MAIN SWITCH,
lock it and remove the key.
2. Clean the vacuum cups with a clean cloth.
3. Check the vacuum cups and hoses and replace them if
necessary.
Replacing vacuum cup As needed.

∅ 45 mm and ∅ 125 mm
5
4
3 6
8
2

Design of the ∅ 45 mm carrier cups Fig. 27650

4
5
3
2
6 7
1 Vacuum cup 5 Fixing nut

2 Nipple 6 Bearing bushing
Design of the ∅ 125 mm carrier cups Fig. 27726

2. Screw the vacuum cup off the nipple.
3. Screw a new vacuum cup onto the nipple.
Pivot suction cup/ Stripper As needed.

suction cup: Replacing the
vacuum cup ∅ 125 mm
7
4
2 3 8

Design of the ∅ 125 mm swivel cups Fig. 27651

4
5
3
2
6 7
1 Vacuum cup 5 Fixing nut

2 Nipple 6 Bearing bushing
Design of the ∅ 125 mm peeler cups Fig. 27726

2. Unscrew the countersunk screws.
3. Replace the vacuum cup.
4. Fit the compression spring.
5. Screw in the countersunk screws.

X axis, Z axis, and Y axis (optional) cable
tow chains at the SheetMaster
Check the cable tow chains Every 2000 operating hours.
1 2 3
1 Z axis cable tow chain 3 X axis cable tow chain

2 Y axis cable tow chain (optional)
Fig. 27655

2. Check the cable tow chains.
3. Replace any loose or missing separators between the chain
links.

5.4 Mechanical components on the
ShearMaster
Scrap container
(see section 2.7)
1 2
1 Conveyor belt 2 Scrap container

Fig. 47957
Check the cut quality of the Monthly

scrap

Risk of injury
¾ Wear gloves.
Warning
The blades' cutting edges are sharp.

Risk of injury
¾ Wear gloves.
Warning

Note
If the blades are so blunt that scrap skeletons cannot be
separated, the machine stops. The scrap skeleton must be
released.
1. Remove container.
2. Check the cut quality of the scrap.
3. If the blades are blunt, notify TRUMPF Service.
Replace the blades.
Conveyor belt
(see section 2.7)
Check conveyor belt for Every 500 operating hours.

damage
1. Check conveyor belt for damage.
2. In case of damage to the conveyor belt, notify TRUMPF
Service.
Check cable tension Every 500 operating hours.

1. Switch to SETUP.
3. Manually start ShearMaster.
– Select 2.Start and press TOGGLE.
4. Manually stop ShearMaster when the conveyor belt has moved
up to the scissor unit.
– Press RESET .
6. Check cable tension.
7. If the cable is too loose, tighten it at the turnbuckle at the end
of the belt.

6. Electrical components
6.1 Maintenance of the electrical

components at the SheetMaster and
scissor table
Switch cabinet of the SheetMaster: TASC

100 control system battery
Replace the TASC 100 Every 2 years.

control system battery

work.
Danger

skin or eyes.

a supervisor.
the machine.
1. Do not switch off the main switch.

3. Remove two screws.
4. Remove the battery.
5. Pull out the battery plug.
6. Connect the battery plug onto the new battery, observing the
polarity.
B380EN06.DOC 6BElectrical components 6-73

7. Install the new battery.
8. Replace two screws.
Light barriers at the scissor table
Clean the light barrier at the Every 500 operating hours.

scissor table
1 Light barrier
Fig. 26916

2. Clean the external lens surfaces with a clean, soft cloth or
cotton wadding. Cleaning agent: alcohol, 30 %.
6-74 6BElectrical components B380EN06.DOC

Chapter 7
Test certificate -
Noise level
TruPunch 5000
Edition: 03/2001
Drawing number: 9120-5-190
Material number: 977020
1. Test certificate ............................................................... 7-2
2. Measurement result....................................................... 7-3
3. Reference workpiece..................................................... 7-4
4. Position of the measuring points................................. 7-5
B380EN07.DOC 1BTest certificate 7-1

1. Test certificate
Noise measurement according to DIN 45635 Part 1

Location, date of measurement Hettingen, 20.03.2001
Measurement room TRUMPF-Hettingen, Assembly
Accuracy class 21
Machine
Type TC 5000 R (1300)
Installation On massive cover 30 cm
(Load capacity 20 kN/m2)
Rubber cork plates at the front and at
the rear
Machine table components Brushes
Measuring device
Sound level meter Brüel + Kjaer, type 2231
Module BZ 7110 integration module
Microphone Free-field microphone 4155
Measuring points
Measuring point arrangement According to DIN 45635, part 1,
fig. 1.3 , p. 19
Dimensions of the reference cube Length l1 = 4.8 m
Width l2 = 5.5 m
Height l3 = 2.2 m
Measuring distance d = 1.0 m
Dimensions of the measuring surface a = 6.8 m
b = 7.5 m
c = 3.2 m
Number of measuring points 29
Position of the measuring points (see section 4, p. 7-5)
Averaging time 32 s
Measuring surface S = 142 m2
Measuring surface level LS = 21.5 dB
Adjusting values
Extraneous noise adjustment K1: 0 dB
2
Environmental adjustment K2A: 1.5 dB
Table 7-1
1
Except for the environmental correction.
2
With K2A = 10 lg(1 + 4 S/A) dB
A = Total surface SV x Sound absorption factor α
A = 4300 m2 x 0.3 = 1305 m2
S = Measuring surface = 142 m2
7-2 1BTest certificate B380EN07.DOC

2. Measurement result
Extraneous noise
Extraneous noise level L"pAeq = 62 dB
Averaging level L'pAeq (dB) at measuring points MP
MP L'pAeq MP L'pAeq
1 81.4 16 83.9
2 85.1 17 82.5
3 81.5 18 83.7
4 82.7 19 82.6
5 79.4 20 82.3
6 82.8 21 80.3
7 79.3 22 82.1
8 83.1 23 78.9
9 83.9 24 82.9
10 83.3 25 84.0
11 82.2 26 83.9
12 81.8 27 81.8
13 81.9 28 81.8
14 80.8 29 85.1
15 81.7
Measuring surface sound pressure
Measuring surface sound pressure LpA,1m = 81.1 dB
level 3
Acoustic power 4
Acoustic power level LWA = 102.6 dB
Workplace-related values
Emission value LpAeq 5 82.8 dB
Pulse contents ΔLI 6 5.2 dB
Table 7-2
3
LpA,1m = L'pA* – K2A
L'pA* = mean sound level from the measurement area L'pAeq
With K1 = 0 dB and K2A = 1.5 dB
LpA, 1m = 82.6 - 1.5 = 81.1 dB
4
With LWA = LpA,1m + LS
5
With LpAeq = L'pAeq – K2A
6
With ΔLI = L'pAIm – L'pAeq
B380EN07.DOC 2BMeasurement result 7-3

3. Reference workpiece
Single part Fig. 13192
Sheet layout Fig. 27469
Material ST 37-2
Material thickness 2.5 mm
Tools used Round 35 mm, flat
Round 10 mm, flat
Slitting tool 5 x 56 mm, angled
Machining time 30 s
Table 7-3
7-4 3BReference workpiece B380EN07.DOC

4. Position of the measuring points
31
80
21
20
10
60
17
00
00
75
68
00
25
56 51
00
10
00
90
43
50 34
37 00
17
75 00
18
• Measuring points
Measuring point corresponds to
the operator's location
Fig. 27468
B380EN07.DOC 4BPosition of the measuring points 7-5

7-6 4BPosition of the measuring points B380EN07.DOC
Chapter 8
Aligning MSL safety light

barrier
procedure ....................................................................... 8-2
2. Set-up example .............................................................. 8-3
3. Alignment procedure..................................................... 8-4

procedure
For proper functioning of the safety light barrier, it is necessary to

align the transmitter, the mirrors on the mirror posts and the
receiver relative to each other.
TRUMPF provides an alignment device for this alignment
procedure.
The laser alignment device corresponds to laser class 2!

Laser radiation can cause irreparable damage to your eyes.
¾ Never look directly into the laser beam.
Warning
TRUMPF alignment device

1 2
Order no. 134023
1 Adapter 2 Alignment device Ar 60

TRUMPF alignment device Fig. 13316
Cross-hairs One cross-hair made of paper is included in the TRUMPF

alignment device. This is cut out from Fig. 6310 (see last page).

• Allen key no. 5.
• Spirit level (approx. 80 cm long).
• Adhesive tape.
8-2 1BAdditional equipment for the alignment procedure B380EN08.DOC

2. Set-up example
An example for the set-up of the transmitter, mirror posts and

receiver is illustrated in the diagram below.
3 E S
2 1
S Transmitter 2 Mirror post 2

E Receiver 3 Mirror post 3
1 Mirror post 1
Fig. 13289
B380EN08.DOC 2BSet-up example 8-3

3. Alignment procedure
Alignment by 2 persons The fine-tuning described below relates to the installation example
above. It must be carried out by two persons, whereby person 1
aligns the receiver and transmitter and person 2, instructed by
person 1, aligns the mirrors for the mirror posts.
If the arrangement of transmitter, mirror posts and receiver are

different from that in the installation example above, steps 1-6
should be carried out in analogous fashion.
Step 1
Preparatory measures • Before beginning with the actual adjustments, the light exit at
the transmitter, the center of the mirrors on the posts and the
light entry at the receiver must be set to the same height (as
measured from the floor).
• Position the transmitter, mirror posts and receiver vertically
using the spirit level, first putting them in approximate
alignment with one another and screwing them down.
• Align the mirrors in the mirror posts approximately parallel to
the recesses in the mirror posts.
• Clean the mirrors (using spirits, window cleaning agent).
• Screw the AR 60 alignment fixture onto the adapter.
Step 2
Aligning the transmitter and • Lock the alignment fixture with adapter into the transmitter.
mirrors of mirror post 1 • Attach the cross-hair to the mirror on mirror post 1.
• Check transmitter's position and, if necessary, adjust it until the
alignment fixture beam hits the center of the mirror on mirror
post 1.
• Attach the cross-hairs to the mirror of mirror post 2.
• Adjust the mirror on mirror post 1 until the alignment device
beam hits the center of the mirror on mirror post 2 (see
Fig. 6309, pos.1).
Step 3
Aligning the mirror of mirror • Attach the cross-hairs to the mirror on mirror post 3.
post 2 • Adjust the mirror on mirror post 2 until the alignment device
beam hits the center of the mirror on mirror post 2 (see
Fig. 6309, pos.1).
8-4 3BAlignment procedure B380EN08.DOC

Step 4
Aligning the receiver and • Fasten the cross-hairs onto the mirror of the receiver.
mirror of mirror post 3 • Adjust the mirror on mirror post 3 until the alignment device
beam hits the center of receiver (see Fig. 6309, pos.1).
• Check the position of the receiver again and, if necessary,
adjust it until the beam of the alignment device hits the center
of the receiver.
Step 5
Aligning further beams • Align the 2nd beam (and any further beams) in the same
manner described in Steps 1 - 4.
Step 6
Functional test • Remove the cross-hairs from the mirror on the mirror post.
• Clean mirror again if necessary.
• Switch ON the machine.
• Activate the safety light barrier.
If the safety light barrier has been properly aligned, the yellow and
green LEDs on the receiver illuminate simultaneously for each
beam.
• If this is not the case, repeat the alignment.
See also "Technical Description MSL Multi-Beam Safety Light

Barrier: Start-up".
Note
The more care taken when aligning, the less chance there is that
problems will arise when operating the safety light barrier.
B380EN08.DOC 3BAlignment procedure 8-5

Mirror correction using 3
correcting screws per mirror
1 Adjusting screws of the mirror

Fig. 6309

Cross-hairs to be cut out Fig. 6310
B380EN08.DOC 3BAlignment procedure 8-7


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Operator's manual

Original operator's manual

Ordering address TRUMPF Werkzeugmaschinen GmbH + Co. KG

For "partly completed machinery" in accordance with the EC Machinery

© TRUMPF Werkzeugmaschinen GmbH + Co. KG

1. For your safety............................................................... 1-3

2. Terminology ................................................................... 1-4

3. Operational safety ......................................................... 1-5

4. Laser safety.................................................................. 1-16

5. Danger due to magnetic fields ................................... 1-17

6. Overview of residual risks .......................................... 1-18

0-6 Contents B380EN00_OHNE FELDF.DOC

1. Planning aid ................................................................... 2-4

2. Installation site............................................................... 2-6

3. Electrical supply .......................................................... 2-12

4. Compressed air supply ............................................... 2-17

5. Operating materials ..................................................... 2-20

6. Transport ...................................................................... 2-26

B380EN00_OHNE FELDF.DOC Contents 0-7

1. The machine concept .................................................... 3-4

2. Technical data................................................................ 3-7

3. The most important assemblies................................... 3-8

4. Tools ............................................................................. 3-14

5. Maximum output tables............................................... 3-48

0-8 Contents B380EN00_OHNE FELDF.DOC

7. Technical information: Automation ........................... 3-71

8. Control system technology ........................................ 3-98

9. Programming ............................................................. 3-100

B380EN00_OHNE FELDF.DOC Contents 0-9

Part 1: Control elements ........................................................... 4-7

1. Control elements: Overview ......................................... 4-7

2. Control panel with color display .................................. 4-9

3. Keyboard ...................................................................... 4-18

4. USB connection ........................................................... 4-19

Part 2: User interface............................................................... 4-20

1. Structure of the user interface ................................... 4-20

2. Machine submodes ..................................................... 4-23

3. Control areas................................................................ 4-25

4. Diagnostics .................................................................. 4-26

5. PRODUCTION Operation............................................. 4-27

0-10 Contents B380EN00_OHNE FELDF.DOC

6. SETUP Operation......................................................... 4-72

B380EN00_OHNE FELDF.DOC Contents 0-11

7. PROGRAMMING Operation......................................... 4-81

8. TOOLING Operation .................................................... 4-87

9. MAINTENANCE/START-UP Operation..................... 4-102

10. DIAGNOSTICS Operation.......................................... 4-106

11. Integrated MDR Operation (optional)....................... 4-109

0-12 Contents B380EN00_OHNE FELDF.DOC

1. Switching the machine on and off ........................... 4-118

2. Executing a program ................................................. 4-120

3. Working with the production plan ........................... 4-127

4. Moving the axes manually ........................................ 4-130

5. Releasing the drive brakes ....................................... 4-131

6. Manual execution of the lubrication cycle .............. 4-132

7. Diagnostic functions ................................................. 4-133

8. Managing master files ............................................... 4-136

B380EN00_OHNE FELDF.DOC Contents 0-13

10. Editing tables based on NC text............................... 4-148

11. TOOLING..................................................................... 4-150

12. Operating the integrated MDR.................................. 4-154

13. Adjusting the pressure foot pressure ..................... 4-158

14. If problems arise ........................................................ 4-159