Chapter 2

Installation conditions
TC L 3020
TRUMPF CNC controller based on the
SIEMENS SINUMERIK 840D control system

The TC L 3020 is a machine designed for cutting material made of

metal with a laser. The machine is intended for processing flat
sheets.
Laser cutting of plastics on the TC L 3020 is strictly prohibited!
Draw. no. 93617-5-20.EN Part. no. 0355201

B494EN02.DOC Installation conditions Version 0 2-1

 Table of contents
1. Installation position....................................................... 2-4
50
40
30
20
1.1 Space requirements......................................................... 2-4
0
10
20
10
0

5 10 20 1.2 Floor requirements........................................................... 2-4

1.3 Weight bearing capacity................................................... 2-6
30
40
50

1.4 Ambient conditions........................................................... 2-7

2. Gas supply ..................................................................... 2-8

2.1 Laser gases ..................................................................... 2-8
Purity ............................................................................... 2-8
Laser gas supply from gas cylinders ............................... 2-8
Central laser gas supply ................................................. 2-9
2.2 Cutting gases ................................................................ 2-10
Purity ............................................................................. 2-10
Cutting gas consumption .............................................. 2-10
Standard pressure cutting.............................................. 2-11
High pressuere cutting .................................................. 2-12
Supply lines ................................................................... 2-13
Cutting gas supply using cylinderes or bundles............. 2-13
Cutting gas supply with gas tank ................................... 2-15

3. Electrical power supply .............................................. 2-18

3.1 Mains supply ................................................................. 2-18
Notes on isolating transformer ...................................... 2-19
3.2 Connected loads, fuse protection, frequency ................ 2-20
3.3 Power consumption ...................................................... 2-21
3.4 Teleservice ................................................................... 2-22
3.5 Network connection ...................................................... 2-22

4. Compressed air supply .............................................. 2-23

5. Working materials ....................................................... 2-24

5.1 Laser gases and cutting gases ..................................... 2-24
5.2 Cooling water ................................................................ 2-24

2-2 Installation conditions Version 0 B494EN02.DOC

 6. Machine transport ....................................................... 2-26
TRUMPF service work................................................... 2-29

7. Planning aid ................................................................ 2-30

B494EN02.DOC Installation conditions Version 0 2-3

 20
1. Installation position

1.1 Space requirements

Layout The layout of the individual system components and the space
required for standard installation of the system are specified in the
respective foundation and installation plan. Also indicated in the
plan is the space required for opening the doors of the control
cabinet, RF generator, exhaust system, cooling unit, and cover of
the laser unit.

A custom foundation and installation plan is needed for non-

standard system configurations.
The supplied installation plan is valid at all times.

1.2 Floor requirements

Evenness The floor on which the system is installed must be as flat and
level as possible.
The difference in height in the area of the basic machine and
the loading/unloading unit must not exceed 10 mm.
Minor unevenness can be compensated for with adjustable legs
or wedge mounts.

Installation surface The entire installation area for the basic machine and the
loading/unloading station must consist of one continuous floor
plate with a smooth surface between the weight support points.
In the case of newly laid floor/ceiling plates, it is imperative e.g.
in the drying process to avoid setting effects which would
exceed the values indicated below.

The offsets which result when the machine is tilted should

not produce laser beam migration of more than 0.5 mm.
The maximum position shift permitted for the two rear legs of
the pallet changer is 1.5 mm.

Special attention must be given to the constantly changing

loads in the immediate vicinity of the machine. This includes
fork-lifts, assembly and disassembly of machines directly next
to the system, shuttle carts, etc.

2-4 Installation position Version 0 B494EN02.DOC

 Floor conditions The floor plate must be a slab at least 200 mm thick, reinforced
on both sides and elastically cushioned (B 25). The soil
coefficient C = 5000 kN/cbm (loess).
The ceiling must be one solid continuous plate at least 250 mm
thick (B 25). See DIN 1045 for quality specifications for the
concrete.
The span width of the ceiling should be less than 7.00 m and
that of supports less than 6.00 m.
In critical cases, it may be advisable before installation to test the
floor and/or ceiling plates for possible deformation (horizontal
and vertical buckling) and to discuss the results with TRUMPF.
Machines causing vibrations during operation must not be
installed in the vicinity of the system.
The maximum permitted acceleration at the support points of
the laser (or basic machine) is 0.1 times the acceleration due to
gravity.

Installation area Fig. 4021E

B494EN02.DOC Installation position Version 0 2-5

 1.3 Weight bearing capacity

Structural stress analysis The load bearing capacity of the floor must be reviewed by a
structural engineer prior to installation. The weights of the individual
system components and the load at the points of support are
specified in the table below.

Component Weight Weight distribution

Max. weight of the basic
machine incl. laser unit,
pallet with support rails
and maximum workpiece
weight
[kg]
Approx. 8800 Weight is distributed on 4 surfaces.
Refer to the respective machine's
foundation plan for the weight load on
each surface.

Max. weight of the Approx. 1400 Weight is evenly distributed on

loading/unloading unitpallet 4 surfaces
changer incl. one pallet with
support rails and max.
workpiece weight

Pallet 250

Support rails 1501

max. workpiece weight 710

Machine control cabinet 700 The edges support the main load

Compact dust extractor 850 The edges support the main load

Control cabinet (laser) 850 The edges support the main load
and HF generator

Cooling unit (without 600 The edges support the main load
cooling water)

Isolating transformer (opt.) 550 The edges support the main load

1
Pallets stacked up to 50 %

2-6 Installation position Version 0 B494EN02.DOC

 1.4 Ambient conditions

Ambient temperature An ambient temperature between +10 C and +43 C must be

maintained for system operation. The temperature must not be
allowed to fall below +4 C when the system is switched off.

Tropical version of the laser When the ambient temperature is between +35 C and +43 C the
system must be equipped with the tropical version of the laser.

Control system cooling The control system is cooled in a closed housing by internal air
circulation. This ensures that components are comprehensively
protected against dirt and dust.
The heat dissipation from the control system housings is normally
performed by external heat exchangers with fans which suck in the
air directly and blow it down the cooling units. Make sure that there
is no excessive air contamination in the region of the fan behind the
control system, as dust on the cooling units greatly reduces the
heat transfer.
Damp rooms are not suitable for operation of control systems,
principally because contactor and relay contacts may become
corroded leading to control errors.

Direct sunlight and drafts from one side should be avoided

(uneven heat distribution), e. g. use blinds if the system is
installed near a window.

To prevent deterioration of beam quality, the installation site of the

laser must be free of particles or substances which absorb radiation
of a wavelength of 10.6 m. These include solvent vapors released
while painting or vapors produced by degreasing equipment.

B494EN02.DOC Installation position Version 0 2-7

 2. Gas supply

2.1 Laser gases

Purity

Laser gas Purity

Helium (He) 4.6 99.996 Vol.-%
Carbon dioxide (CO2) 4.5 99.995 Vol.-%
Nitrogen (N2) 5.0 99.999 Vol.-%

Laser gas supply from gas cylinders

The simplest and most economical method of laser gas supply

is to use individual cylinders.
The gas flow is interrupted when changing cylinders or cylinder
groups.

Helium (He) Carbon dioxide Nitrogen (N2)

(CO2)
Identification:
Bottle colour Gray RAL 7000 Gray RAL 7000 Green RAL 6001
Label He 4.6 CO2 4.5 N2 5.0
Gas consumption [l/h]:
TLF 3200 13 1.0 6.0
1
Inlet pressure on 5-7 1
5-7 5-71

gas mixer [bar]

Supply lines:
Nominal width [mm] 6 6 6
2
Max. length [m] 10 10 10
Hose material PTFE or PE PTFE or PE PTFE or PE
Valve connection W21.80 x 1/14" W21.80 x 1/14" W24.32 x 1/14"
in accordance with in accordance with in accordance with
DIN 477 no. 6 DIN 477 no. 6 DIN 477 no. 10
Pressure reducer specification:
Design Two stage with Two stage with Two stage with
special steel special steel special steel
membrane membrane membrane
Starting pressure [bar] 200 200 200
Back pressure [bar] 0.5-6 0.5-6 0.5-6
Min. volume rate of flow [Nm/h] 5 5 5
Shut off valve / flushing valve to be pre-switched to be pre-switched to be pre-switched

1
The input pressure at the gas mixer must not exceed >7 bar!
2
For greater distances, rigid piping of stainless steel or copper (ultra pure gas).

2-8 Gas supply Version 0 B494EN02.DOC

 All gas supply lines must be completely clean. The hoses must not
be cleaned with solvent. Do not use lubricants when attaching
hoses. The utmost cleanliness should be observed during all
maintenance work.

Central laser gas supply

Cylinder batteries are recommended for wall mounting and for

uninterrupted operation.
Switchover can be manual or automatic.
Copper or stainless steel pipes (refrigerator quality) must be
used for laser gas supply.
The exposed ends of the pipes must be sealed to prevent
contamination during transport and storage.
The required connection joints must be brazed under inert gas.
Assure yourself that no flux residue remains on the pipe
interior.
Alternatively, clamping ring connections of the same material
can be used.
The pipes, once installed, must be tested for leaks before being
put into operation.
The pipes should then be flushed with inert gas and laser gas
(final purging with nitrogen); this serves to flush moisture and
remaining gas from the lines.
The gas supplier must be consulted in all cases.

B494EN02.DOC Gas supply Version 0 2-9

 2.2 Cutting gases

Purity

Cutting gas Purity

Oxygen (O2) 3.5 99.95 Vol.-%
1
Nitrogen (N2) 5.0 99.999 Vol.-%

In special cases, nitrogen with a 4.6 (99.996) purity level or

other purity levels can be used providing the following limit
values are not exceeded:
O2 100 vpm
H2O 5 vpm
CnHm 1 vpm

Cutting gas consumption

Cutting gas consumption varies with the:

Nozzle diameter
Cutting gas pressure
Duration of laser cutting process

Estimating the gas The expected cutting gas consumption can be approximately
consumption estimated with the aid of the consumption rates for standard and
high pressure cutting presented below. A differentiated estimate for
specific materials and sheet thicknesses is possible with the help of
data collection on your machine.

1
When using low purity nitrogen, oxygen contamination exceeding 100 vpm may cause discoloration of the cut edges in high
pressure cutting. This can be avoided only by using nitrogen with a purity of 5.0 or by using a cutting gas supply with the
gas tank (the nitrogen purity is generally 5.0 in the gas tank).

2-10 Gas supply Version 0 B494EN02.DOC

 Standard pressure cutting

Standard pressure cutting means cutting at a pressure of 6 bar.

Oxygen and/or nitrogen is required as a cutting gas.

During standard pressure cutting with O2 (Pmax = 6 bar), the

minimum line pressure to be set on the instrument panel is 8 bar at
a gas consumption of 10 Nm3/h.

Maximum cutting gas

consumption per hour for
permanent cutting

d Nozzle diameter
V/t [Nm/h] Gas volume per time unit in Nm/h
p [bar] Pressure in bar (compared with the external pressure)

Maximum gas consumption per hour at a laser duty cycle of 100 % Fig. 8809

B494EN02.DOC Gas supply Version 0 2-11

 High pressure cutting

Cutting at a pressure above >6 bar is referred to as high pressure

cutting. The cutting gases used are nitrogen and/or oxygen.
High-pressure cutting is available as an option for processing
stainless steel and aluminium alloys.

During standard pressure cutting with O2 (Pmax = 12 bar), the

minimum line pressure to be set on the instrument panel is 15 bar
at a gas consumption of 20 Nm3/h.

During high pressure cutting with N2 (Pmax = 20 bar), the minimum

line pressure to be set on the instrument panel is 27 bar at a gas
consumption of 55 Nm3/h.

Maximum cutting gas


consumption per hour for
G PP
permanent cutting G PP
G PP
G PP






9W>1PK@




       
S>EDU@

d Nozzle diameter
V/t [Nm/h] Gas volume per time unit in Nm/h
p [bar] Pressure in bar (compared with the external pressure)
Maximum gas consumption per hour at a laser duty cycle of 100 % Fig. 23507

2-12 Gas supply Version 0 B494EN02.DOC

 Supply lines

The user must provide the gas supply connections up to the

instrument panel at the machine.
Pipes are to be used for the entire gas installation from the gas
cylinder or from the central gas tank to the machine.
The evaporator must be designed in accordance with the
maximum consumption of all connected machines.
The external gas installation must be designed in such a way
that the supply lines to the instrument panel and the panel itself
cannot ice up. Consequently the line from the evaporator to the
instrument plate must be as short as possible.
The gas temperature must not exceed 50 C. This applies
above all if the necessary gas pressure is to be generated
using a pressure increasing device!

Pipes Oil and grease-free copper pipes of special quality ("refrigerator

quality", i.e. inert-soldered using plain forming gas) are
adequate for the cutting gases.
Stainless steel pipes are not essential.
To prevent the pipes becoming contaminated during transport
and storage, the ends should be securely closed.

Tube Nominal Applications

dimen- width
sions (mm)
" 13 From the tapping point to the machine; reduce to
15 x 1 connection diameter of 10 x 1 for N2 or 8 x 1 for O2
3/8" 10 Up to 10 bar; preferably O2
12 x 1
5/8" 16 Over 10 bar; preferably N2 high pressure
18 x 1
" 19 For ring circuits supplying up to two laser units and for
22 x 1.5 lines from evaporator to ring circuit
1" 25 For ring circuits supplying more than two laser units and
28 x 1.5 for lines from evaporator to ring circuit

For ring circuits: a ball valve must be inserted between each

branch line in order to be able to cut off sections of lines!

Please read the notes under "Central laser gas supply" for
installation and for testing the pressure and seals.

B494EN02.DOC Gas supply Version 0 2-13

 Cutting gas supply using cylinders or
bundles

Individual cylinders or
individual bundles
Gas supply with pressure reducers for individual gas cylinders
or cylinder groups is the simplest and most economical method
of gas supply; because of the high-volume consumption,
however, more handling is necessary.
The gas flow is interrupted when changing cylinders or cylinder
groups.
This supply method is not well suited to N2 high pressure
cutting.

Cylinders or Uninterrupted operation with cylinder or cylinder group batteries

bundle battery requires switching devices, also for cylinder change.
1
Switchover can be manual or automatic.
The fittings for both battery units are virtually identical.
Bottle group units are frequently installed at some distance
away from the laser machine. The use of an intake pressure
reducer in the vicinity of the laser system is recommended.
Group comprises of 12 cylinders = 120 m of gas.

O2 O2 N2
standard High High
2
pressure pressure
Projected supply pressure to 8 15 27
be set at instrument panel
[flow pressure in bar]

Max. cutting gas pressure 6 12 20

[bar]

Volume rate of flow3 [Nm/h] 10 20 82

Nozzle diameter [mm] 1.7 1.7 2.7

Cutting gas O2 N2
High pressure
Specification of two level
gas bottle pressure
regulator
Pre-pressure [bar] 0-200 0-200
Max. permissible back pressure 25 40
[bar]
Min. throughflow rate [Nm/h] 30 90
Other requirements Suitable for oxygen; oil and grease-free
oil and grease-free

Always install a pressure safety device in the form of

specified pressure regulators on the supply unit!

1
The use of a signaling unit is advisable for automatic changeover, without it, the battery system could be drained empty at
both sides without this being detected.
2
This is only necessary for special uses; e.g. laser cutting with high pressure oxygen.
3
The volume rate of flow is reached when maximum cutting gas pressure is selected and the nozzle diameter is specified.

2-14 Gas supply Version 0 B494EN02.DOC

 Cutting gas supply with gas tank

The use of a gas tank is recommended for steady gas supply if

the gas consumption exceeds approx. 200 Nm3/week.
The optimum tank volume depends on the consumption rate
and on-site conditions.
An agreement must be reached with your gas supplier.
For high-pressure cutting with nitrogen:
Do not insert a tapping point pressure regulator between
the gas tank and the machine.
A stop valve must be inserted between the gas tank and
the machine.

O2 O2 N2
Standard High High
1
pressure pressure pressure
Tank:

Nominal pressure [bar] 18 36 36

Max. tapping pressure [bar] 14 16 29

O2 O2 N2
Standard High High
1
pressure pressure

Projected supply pressure to 8 15 27

be set at instrument panel
[flow pressure in bar]

Max. cutting gas pressure [bar] 6 12 20

Volume rate of flow2 [Nm/h] 10 20 82

Nozzle diameter [mm] 1.7 1.7 2.7

1
This is only necessary for special uses; e.g. laser cutting with high pressure oxygen.
2
The volume rate of flow is reached when maximum cutting gas pressure is selected and the nozzle diameter is specified.

B494EN02.DOC Gas supply Version 0 2-15

 O2 O2 N2
Standard High High
1
pressure pressure pressure
Specification for
pressure
regulation:

Pressure level 1
(tank)

Safety pressure Optional Recommended Recommended

2
regulating station

Post reduction pressure 2.5-14 2.5-16 0.5 30

[bar] on take-off point
pressure regulator (O2) or
dome pressure regulator
(N2)

Flowrate [Nm/h] >60 >100 >120

Pressure level 2
(take off point)

Take off point pressure Recommended Recommended Not

regulator recommended

Pre-pressure [bar] PN 25 PN 40 -

Post reduction pressure 0-16 4-25 -

[bar]

Flowrate [Nm/h] 30 120 -

Other requirements Suitable for Suitable for -

oxygen; free of oxygen; free of
oil and grease oil and grease

With all gas installations it must be ensured that the gas supply
lines are not placed together with the electrical cables! Otherwise
fire may result if a gas line is damaged by a short circuit or such
like. For this reason the gas supply lines must always be guided
separately to the metal instrument plate!

We strongly recommend that the customer consult his gas supplier

regarding the gas installation.

1
This is only necessary for special uses; e.g. laser cutting with high pressure oxygen.
2
The safety pressure regulating station is installed near the tank. This guarantees uniform pressure in the supply network.
The installed safety valve ensures that the gas is blown out of the unit should an error occur. This also prevents danger
arising in the laser system area due to concentration of oxygen (O2) or oxygen depletion (N2).

2-16 Gas supply Version 0 B494EN02.DOC

 The relevant standards (e.g. DIN 477 No. 6, DIN EN 559,
DIN 8541 section 3, VBG 15, VBG 62 46 + 47) must be
strictly observed.

B494EN02.DOC Gas supply Version 0 2-17

 3. Electrical power supply

The unit is designed for the following rated voltages:

Rated voltage Frequency

400 V 10 % 50 Hz 1 %

460 V 10 % / -5 % 60 Hz 1 %

If the nominal voltage deviates from 400 V or 460 V, an

1
isolating transformer must be installed.
The electrical supply of the system requires a 4-pole connec-
tion with copper cable (L1, L2, L3 with Z-twist; production unit).
The mains supply is connected as shown in the layout on the
control cabinet of the machine. System components (laser,
suction unit, cooling unit) are supplied from there.

Electrical power supply Connection cable

Cable Cross section Earth wire
Regulation: Regulation: Four Design in Design in
pole copper cable accordance with accordance with
Design acc. to
(L1, L2, L3, PE) VDE 0100 VDE 0100
DIN EN 60204-1/4.3.1
part 430 part 540
(IEC 364-4-47) (IEC 364-5-54)

3.1 Mains supply

The system may not be connected to a circuit shared by welding

machines (temporary voltage peaks). A direct line from the distri-
bution point should be wired in this case and if the circuit is heavily
loaded.

Residual current protection If a residual current protection system with direct or indirect contact
system is used on the line side, only type B is permitted. See EN 50178
pt. 5.2.11.2 (VDE 0160, April 1998 edition).
If, when using a residual current circuit breaker, the leakage current
of the machine is larger than the set residual current, the machine
and line must be separated with an isolating transformer.
See EN 50178 pt. 5.2.11.1 (VDE 0160)

Network types The machine must be connected via an isolating transformer with IT
and TT network types and with asymmetrical networks (one phase
grounded).

1
If the rated voltage is 380 V or 415 V at 50 Hz, the tolerance of the network must be determined. If the tolerance is found to
be between 360 V 440 V, an isolating transformer is not necessary.

2-18 Electrical power supply Version 0 B494EN02.DOC

 Notes on isolating transformer

The following must be observed if the machine is equipped with an

isolating transformer:
The cable from the isolating transformer to the control cabinet
of the machine must be provided by the customer.
The location of the isolating transformer must be specified by
the customer.
The dimensions of the isolating transformer are:
Length: 1050 mm
Width: 750 mm
Height: 1400 mm
The isolating transformer must be installed in such a way that
access to the hanging door on the front side (door with type
plate) is kept free. A safety distance of 800 mm must be
observed.

1050
750

1
800

1 Isolating transformer 2 Safety distance

Space required for the isolating transformer Fig. 22107

The manufacturer's documentation must be observed for the

isolating transformer: Series transformer MD 90000, Roller and
Fischer company; Mat. No.: 142586. The documentation is
available in German, English and French.

B494EN02.DOC Electrical power supply Version 0 2-19

 3.2 Connected loads, fuse protection,
frequency

Connected loads of the machine with TLF 3200

1
Total connected load inc. cooling unit 68
(kVA)
Max. fuse protection of the complete system 100
(at 400 V and 460 V) (A)
Total connected load without cooling unit 48
(kVA)

Max. fuse protection of the complete system 80

without cooling unit (at 400 V) (A)
Maximum permitted interruption of the
nominal voltage (ms) See EN 60204, Part 1, Point 4.3.2, Alternating Current Supply.

Tank heating (option) The following applies if the installation is equipped with the tank
heating option at the cooling unit:
The voltage supply must be provided by the customer via a
separate connection on the cooling unit.
In this case, the connected load of the complete system can be
reduced to the connected load of the cooling unit.
The connection cable must be provided by the customer. It can
be connected via the socket of the cooling unit.

TLF 3200
Connected loads of the cooling unit [kVA] 21

Fuse protection at 400 V [A] 50

1
If requested, an evaporation cooling unit can be installed. Further information can be found in "Information on the
evaporation cooling unit"

2-20 Electrical power supply Version 0 B494EN02.DOC

 3.3 Power consumption

80
TLF 2000
TLF 2700

P [kW]
70
TLF 3200
TLF 4000
60

50

40

30

20

10

0
1% 100%
P [%]

P [kW] Power consumption of machine and laser in kW

P [%] Laser power in % of maximum laser power
Power consumption of the machine is dependant on Fig. 24032
laser power. Suction unit and cooling unit are taken into account.

B494EN02.DOC Electrical power supply Version 0 2-21

 3.4 Teleservice

The machine control cabinet is fitted ex-works with the following

interfaces:
Telephone interface
TAE6-N coupling
Network interface
Either BNC or RJ45, according to customer requirements.

The following work must be completed by the customer:

Installation of a telephone outlet box by the respective
telephone company.
It must be possible to obtain a direct exchange line for the
modem via a number code.
The modem must be accessible through a direct dial extension
number. If not, a separate trunk line will be needed.

3.5 Network connection

Depending on the customer's requirements, either a BNC connector

RG58 or a line with RJ45 connector is installed in the control cabinet for
linking the machine controller to a network (e.g. to connect it with a
programming system).

If several machines are integrated into the network, a personal hub

(network distributor) is required. This is located in the switch cabinet
of the machine and must be supplied with AC current by the
customer, because the distributor must also function when the
machine is switched off. The voltage supply must be carried out as
described in the following power system control projects.

In power supply control projects in association with CELL

SERVERS, a voltage supply must be supplied by the customer next
to the PC cabinet.
Voltage supply (except in USA and Canada) 230 V with
grounded outlet socket. Grounded coupling is delivered with
machine.
Voltage supply in USA and Canada 115 V with USA standard
socket.

Network tolerance The same tolerances for nominal voltage and frequency described
in Point 3 apply to both voltage supplies.

2-22 Electrical power supply Version 0 B494EN02.DOC

 4. Compressed air supply

The compressed air connection may be flexible or made of

fixed piping on the machine.
The compressed air connection must be equipped with a hand-
operated 3/2 directional valve with bleeding on the machine side.

Connection Required mains supply pressure 7-14 bar

consumption (necessary volume rate of flow approx. 42 m/h =

according to ISO 1217 or DIN 1945) 700 l/min

Minimum nominal width of the supply lines " (DN13)

Ring cable length Max. 50 m (due to

condensate formation)

Ring hose diameter Min. 1" (26 mm)

Length of connection line from ring circuit to Max. 5 m

instrument plate

The compressed air at the intake point must meet the following
requirements:

Characteristics Requirement Quality class Recommendation

ISO 8573-1
Free of condensate cooled to +7 C 5 Cold dryer
(pressure dew point)
Free of dust Max. particle size: 4 Air filter at the intake side
15 m
Max. particle density:
8 mg/Nm
Free of oil Max. oil content: 4 Small oil volume or oil-free
5 mg/Nm compressing compressors

Compressor A suitable compressor must be installed if the compressed air

supply is not adequate. Due to the risk of condensate build-up, the
maximum distance between the compressor and the basic machine
must not exceed 50 m.

B494EN02.DOC Compressed air supply Version 0 2-23

 5. Working materials

The customer must provide the operating materials described in the

following points before the machine is delivered:

5.1 Laser gases and cutting gases

The gas types and purity specifications, see section "Gas supply.

5.2 Cooling water

Water is needed to cool the laser, RF generator and optical

components on the machine.
Cooling is carried out by two cooling circuits, one made of copper
and one made of aluminium.

Requirements for the Demineralized, deionized or distilled water. The cooling water for
cooling water: the machine start-up is to be provided by the customer.
Before being transported to the customer, the cooling circuit
of the laser is flushed with "purest ethylene glycol", if the
following conditions apply:
The machine is delivered between November 1 and April 30.
The machine is transported by ship or plane.
The cooling circuit of the machine must therefore be flushed when
the machine is started up at the installation site. In this case, the
customer must provide 60 % more demineralized, deionized or
distilled water than indicated in the table.

Copper Aluminium
cooling circuit cooling circuit
Cooling water quantity [l]:
TLF 3200 55 320
Conductivity [S/cm]:
Conductivity of freshly 10 10
changed water
Cooling water conductivity 200 600
limit during operation
Carbonate content [mg/l] M 100 M 100
Colour Colourless Colourless
Cloudiness None None
Odor Odorless Odorless

2-24 Working materials Version 0 B494EN02.DOC

 The specified chemical/physical properties must be adhered
to at all times. Consult your supplier with regards to this
matter.

Storage Demineralized water should be stored only for a short time so

as not to impair the water quality.
The water must be transported in clean plastic containers
(without precipitates, no build up of odor).

Handling Avoid all unnecessary contact with the water (e.g. with hands).
Contact with foreign substances other than those specified by
TRUMPF impair the quality of the water.
Additional equipment for filling water such as pumps, hoses or
stop cocks should be used exclusively for operation with the
system water.
The demineralized water must undergo a simple inspection
regarding colour, cloudiness and odor before filling.
Colour/cloudiness: Any cloudiness (e.g. caused by
suspended matter, fibres, flock, particles) means that the
water is contaminated. The system should not be filled with
this water in such cases!
Odor: Any deviation from the neutral odor means that the
water is biologically contaminated. The system should not
be filled with this water in such cases!

Outdoor installation of the If the cooling unit is installed outside in areas at risk of frost, the
cooling unit antifreeze "purest ethylene glycol", is added to the cooling water.
The mixture proportions depend on the respective temperature
conditions at the installation site:

Temperature [C] Up to 15 Up to 24
Weight per cent [%] 30 40
Per cent by volume 27 35
[%]

A cooling unit which has had "purest ethylene glycol" added

to its cooling water once before must always be filled with
this antifreeze even in summer.

Any other operating materials required for machine start-up will be

supplied with the installation.

B494EN02.DOC Working materials Version 0 2-25

 6. Machine transport

All machine components must be examined upon receipt for

damage incurred during transit. Visible transport damages must be
recorded on the bill of lading and countersigned by the truck driver.
Hidden transport damages must be reported to the insurance
company and to TRUMPF within 6 days, at the latest.

The customer must arrange and provide the means to convey the
equipment from the truck to the final installation site.
The transportation path to the machine installation position must be
decided well in advance of delivery. In particular, check gateways,
potholes, boarded cabling excavations, whether the ground is
suitable for supporting armoured rollers etc.
The machine dimensions according to the installation plan should
be taken into account in deciding the transportation path!

Dimensions of system Component Length Width Height

components incl. transport [mm] [mm] [mm]
devices
Machine body incl. laser unit 5800 3200 23001

Of the loading/unloading 3390 250 520

unit

Double cabinet for control 1405 800 2000

system and RF generator

Control cabinet of the 1200 950 2000

machine

TLF laser cooling unit 1750 800 2000

Compact dust extractor 1350 1280 2000

Isolating transformer 1050 750 1400

(optional)

1
incl. armoured rollers for transportation

2-26 Transport Version 0 B494EN02.DOC

 Auxiliary and handling The basic machine and pallet changer are delivered with a
devices crane girder (on loan) to facilitate transport, Id. No. 124949
Crane truck for machine and accessory systems. A hydraulic
crane truck with at least 80 t hoisting power is recommended; if
local conditions require a greater lever arm, a crane truck with
greater hoisting power should be used instead.
Fork-lift truck (carrying power 2.5 t)
Gantry crane or
Armoured rollers (1 steerable and 2 rigid)
At least 2 hydraulic hoisting jacks with min. 5 t lifting load (min.
attachment height: 30 mm)
Crow bar (1 m) and extension

Detailed conditions for transporting the equipment are

provided in the respective transport regulations 93614-8-20.

A copy of the transport regulations can be found in a clear

plastic pouch at the machine.

Work to be performed by the customer

Unloading the Unloading the machine from the truck
machine from the with a truck crane with corresponding
truck hoisting power.
Remove the transport beams from the
machine legs while the machine is
suspended from the crane.
The system must not be lowered
onto the ground without supports.
Otherwise the underside of various
components may be damaged!
In the interests of preventing damage
to the collecting drawer when the
machine is stepped, ensure that the
leg plates are at least 100 mm above
the ground. This minimum clearance
must also be guaranteed while the
machine is being transported to its
installation position.
The control cabinets, cooling unit, suction
unit, HF generator and of the loading and
unloading station can be transported
directly from the truck to the machine
installation position using a fork-lift truck.

B494EN02.DOC Transport Version 0 2-27

 Work to be performed by the customer
Transporting the Transport the machine from the yard into
machine from the the factory hall on armoured rollers.
yard to the To continue to the installation site, either a
installation gantry crane of sufficient carrying capacity
position or armoured rollers can be used.
Installing the The hydraulic hoisting jacks are required
machine in the to position and align the machine at the
installation installation position when using armoured
position rollers.
Positioning the machine on armoured
rollers next to the actual installation
position.
If the site conditions do not permit this,
then TRUMPF customer service
(tel. + 49 (0)7156/303-476 or fax + 49 (0)
7156/303-613 or -695) must be informed
as soon as possible. In this case the
machine can be placed on the delivered
installation elements at the final
installation site after consultation.
The control cabinet, cooling unit and
compact dust extraction unit can be
positioned at the final installation position
if this does not hinder installation.
The floor requirements at the instal-
lation site must be determined
according to the requirements of these
installation conditions.

2-28 Transport Version 0 B494EN02.DOC

 TRUMPF service work
Levelling the machine The machine is levelled by TRUMPF service engineers.

Machine start-up The machine started up by TRUMPF specialists. This includes the
installation of the system components in conformity with the
installation plan, connecting the machine to the power supply,
instructing the personnel and testing machine functions.

B494EN02.DOC Transport Version 0 2-29

 30 31 7. Planning aid

The plan aid below provides an overview of the work and

preparations to be undertaken by the customer.
For details, refer to the corresponding subsections of the installation
conditions.

Time before machine Planning Measures

delivery criterion

15 weeks Personnel and Appoint a member of staff to be respon-

training sible for the machine commissioning pre-
parations.

Appoint the operating and maintenance

staff, the programmers and enroll them in
the necessary training courses.

Appoint a laser safety officer.

14 weeks, Installation site Determine the machine's final location.

at the latest ... Allow for space requirements as specified
20
in the installation plan.

Check the floor requirements (floor quality,

evenness, oil-proof floor without expansion
joints).
Take the weight and dimensions of the
machine into account.

Check that the requirements for the ambient

conditions are met (ambient temperature,
insolation, purity of ambient air.)

Examine the transportation route

(doorways, potholes, boarded cable
excavations, clearance space around
corners, etc.)
12 weeks, Electrical power Install the electrical connections at the
at the latest ... supply installation position. The conductor cross-
section and the fuse protection should be
made according to legal guidelines.

2-30 Planning aid Version 0 B494EN02.DOC

Time before machine Planning Measures
delivery criterion

12 weeks, Gas supply Arrange for installation of laser gas and

at the latest .... cutting gas supply to the installation site.
Determine the type of gas supply
(cylinders, cylinder groups, gas tank).
Note the additional fittings required
(e.g. two stage pressure reducer).
Consult your gas supplier to make a layout
for the gas lines.
12 weeks, Compressed air Install a compressed air supply at the
at the latest ... supply installation site (connection, purity,
compressed air requirement).

4 weeks, Operating Materials Stocking up operating materials

at the latest ... Laser gases
Cutting gases
Operating material for the cooling unit

4 weeks, Laser safety glasses Order laser safety glasses for servicing
at the latest ... work.

4 weeks, Transportation aids Ensure that the required transportation aids

at the latest ... are available.

B494EN02.DOC Planning aid Version 0 2-31

2-32 Planning aid Version 0 B494EN02.DOC