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B561EN TruBend
B561EN TruBend
. This safety device prevents the tools from falling out of the
tool clamping. The lock can be released by pushing a button:
The upper tools can be changed quickly and safely in vertical
position.
Shorter tool set-up times because tools must no longer be
removed laterally from the upper tool holder.
TRUMPF upper tools can be inserted on both sides. This results in
a considerable reduction of tool costs particularly with elbowed
tools.
The upper tool holder for TRUMPF tools is self-centering. Upper
tools do not have to be aligned by means of an idle stroke before
the first bending.
4.2 Programming the tools
All tools and special tools from TRUMPF that can be used for the
TruBend Series 3000 have already been stored in the control
system.
Upper and lower tools which are not yet contained in the control
system (e.g. special tools, tools from other manufacturers) can be
programmed directly into the control system.
TRUMPF bending tools
LASERdur
Tools of varying lengths
Safety-Click safety element
Using for folding over
Self-centering
3-24 5BThe most important options B561EN03.DOC
5. The most important options
TRUMPF Quick Clamp (for upper tools) Tool clamping
Pneumatic tool clamping
4-axes backgauge Backgauge
5-axes backgauge
Additional foot switch
Manual operator console
Network connection
TRUMPF BendGuard
Light curtain
5.1 Additional foot switch
Two operators can work at the machine if an additional foot switch
is connected.
Tab. 3-5
B561EN03.DOC 5BThe most important options 3-25
5.2 Manual operator console
The manual operator console consists of the following operating
elements:
BEAM DOWN (2x) manual button.
EMERGENCY STOP impact button.
BEAM DOWN foot switch.
EMERGENCY-UP foot switch.
1 Indicator lamp
2 EMERGENCY STOP impact
button
3 Manual button
4 BEAM DOWN foot switch
5 EMERGENCY-UP foot switch
Information
The manual operator console down is active if the indicator
light lights up.
The EMERGENCY STOP impact button and the
EMERGENCY-UP foot switch are always active.
Fig. 52438
3-26 5BThe most important options B561EN03.DOC
Manual buttons and foot switch BEAM DOWN are active. Both the
manual buttons must be pressed at the same time to move the
beam (with rapid speed up to the mute point). From the mute point,
the BEAM DOWN foot switch also needs to be pressed to move
the beam at the operating speed (max. 10 mm/s).
5.3 Network connection
Programs, tools and machine parameters can be directly imported
to the control system from a network drive or saved from the
control system onto a network drive.
The advantages are obvious:
Memory capacity for the bending programs can be expanded
as required.
Backup by the external data memory prevents data loss.
Data can still be managed using diskettes, as before.
5.4 TRUMPF BendGuard
Note
Working at a rapid speed >10 mm/s is permitted only when an
optoelectronic safety device is used.
TRUMPF BendGuard enables work at rapid speed without impair-
ing the safety of the operating personnel. The area below the up-
per tool is thus monitored constantly by two moving bands of three
visible red laser beams. If the light beams are interrupted, the
downward movement of the beam is stopped.
TRUMPF BendGuard is a non-contact protection device (BWS) of
type 4 according to EN 954 with integrated springback verification
device.A safety level in accordance with EN 12622 (2001) 5.3.2(f)
has been achieved.
Two-hand operation
operating mode
Unlimited size of the
memory capacity
Innovative safety concept
B561EN03.DOC 5BThe most important options 3-27
Three parallel laser beams shine in front of the upper tool at a
distance of 4 mm (laser light A) and 14 mm (laser light B) under the
upper tool tip and serve as hand and finger protection. The
effective width of the laser band starts 20 mm in front of and ends
20 mm behind the upper tool tip.
Note
Laser light A is only visible when the foot switch is pressed.
1 2 3 4 5 6
1 Transmitter
2 Laser light A
3 Laser light B
4 Lower tool
5 Upper tool
6 Receiver
Principle of the TRUMPF BendGuard
The 40 mm wide laser lights are divided into three individual
beams:
An approximately 20 mm wide laser light in front of the upper
tool tip.
A laser beam with circular cross-section under the upper tool
tip.
An approximately 20 mm wide laser light behind the upper tool
tip.
In this way BendGuard knows if the light interruption should be
before, exactly under or behind the upper tool tip. If the laser light
is interrupted, the beam is stopped.
The upper tool can be moved at rapid speed up to the mute point
(switch-over point from rapid speed to working speed), after which
the bending process takes place at working speed.
When bending boxes or troughs, the two outer laser beams can be
deactivated (nesting mode). This avoids collision contours through
side walls that have already been bent. Operator safety is ensured
by the middle beam.
Principle
Fig. 30830
3-28 5BThe most important options B561EN03.DOC
If the laser beams hit an obstacle, the machine stops. When the
obstacle is removed, the bending procedure can be continued by
pressing the foot switch again. This ensures 100% hand and finger
protection in the area of the outward laser beam.
1 Laser lights A and B
2 Obstacle
3 Mute point
4 Workpiece
Rapid speed is permissible only with foot operation; the hands
remain free for handling the tools.
Optimal productivity; no reduction in cycle time compared to
operation without this safety application.
Choice between normal mode with three beams and nesting
mode with one or two beams.
Intermediate storage in the provided holding fixture in the direct
vicinity of the place of use.
Quickly adjustable to all standard tool heights.
User friendly, because the programming functions and displays
are integrated into the standard control system.
Programming errors during the determination of the mute point
are monitored and cause no safety risk.
In addition to light beam interruption, TRUMPF BendGuard also
monitors the speed of the beam at rapid speed and working speed,
the springback of the beam and the position of the mute point.
TRUMPF BendGuard is laterally mounted on the beam and can
thus be easily moved upwards for replacing an upper tool.
Fig. 31069
Advantages
Further functions
Fastening to the machine
B561EN03.DOC 5BThe most important options 3-29
Functions of the magnetic plate
This magnetic plate is magnetic. There is a functional area on the
black rear side:
Millimeter scale from 0 to 20 mm.
Magnetic plate
The magnetic plate is used to check the position of the laser beam
under the upper tools. To do this, the millimeter scale is printed on
the magnetic plate.
The following points are only necessary for a sheet thickness
<1 mm or die widths 40 mm. Magnetic plates are not required in
all other cases:
Simulation of the sheet thickness:
The magnetic plate is slid upwards by the thickness of the
sheet when the mute point is being determined. To do this,
the millimeter scale is printed on the magnetic plate.
Shielding the laser beam after the mute point:
TRUMPF BendGuard requires and monitors the correct
definition of the mute point. The laser beam must be
interrupted after reaching the mute point. Otherwise, the
bending cycle is not completed.
This interruption is caused by placing the magnetic plate
on the lower tool laterally. This hinders the laser beam
from shining through the lower tool.
Fig. 35733
Position of the laser beam
Further functions
3-30 5BThe most important options B561EN03.DOC
Indicator lamp on the transmitter
A red indicator lamp is located on the BendGuard transmitting unit:
Lit up continuously: the indicator lamp is lit up continuously
once the mute point has been reached or when the laser beam
is interrupted.
Slow blinking: In the nest bending mode (BendGuard modes 2
and 4) the indicator lamp blinks slowly until the mute point has
been reached or until the laser beam has been interrupted.
Rapid flashing: the indicator lamp flashes rapidly in the event
of malfunctions or screen messages.
Safety notes
Warning
Risk of injury!
Do not touch live parts.
Do not open any of the TRUMPF BendGuard parts.
Warning
Class 1 laser light!
Risk of injury to the eyes.
Never look directly into the laser.
The laser light is harmless to the body surface.
TRUMPF BendGuard requires and monitors the correct definition
of the mute point. The laser beam must be interrupted after
reaching the mute point. Otherwise, the bending cycle is not
completed.
This interruption is caused by placing the magnetic plate on the
lower tool laterally. This hinders the laser beam from shining
through the lower tool during the bending cycle.
From the mute point on, it can not differentiate between loading
your finger or a metal sheet, as the laser beam is switched to mute
mode. But if the mute point has been correctly defined, it should
not be possible to jam your finger in the narrow gap between upper
tool and the lower tool.
Safety after the mute point
B561EN03.DOC 5BThe most important options 3-31
An inspection must be carried out every day to determine whether
TRUMPF BendGuard is working perfectly. Do not trust the setting
without first checking yourself.
1. Interrupt the laser beam with an object during the closing
motion in rapid speed.
The downward motion of the beam must come to a stop.
2. Check the mute point.
Keep the transmitter and receiver panes free of dust, dirt, and
oil.
Avoid scratches in the beam area.
Clean the window only with a soft, slightly damp cotton cloth.
5.5 Light curtain
Note
Working at a rapid speed >10 mm/s is permitted only when an
optoelectronic safety device is used.
The light curtain is an optoelectronic safety device for the operator
and enables operation of the machine at rapid speed (220 mm/s).
The light curtain is attached in front of the beam and press table
and protects against obstacles from a length of 14 mm.
If the light curtain is interrupted, the beam stops and moves to the
upper dead point in order to avoid injuries.
Checking the function before
starting work
Avoiding contamination
Optimum protection without
loss of productivity
3-32 5BThe most important options B561EN03.DOC
B561EN04.DOC 0BOperation 4-1
Chapter 4
Operation
1. Description of the operating elements ........................ 4-3
1.1 Foot switch....................................................................... 4-3
1.2 Manual operator console (optional)................................. 4-4
1.3 Operating elements at the switch cabinet........................ 4-5
1.4 Operating elements for the control system...................... 4-8
1.5 User interface structure................................................. 4-10
Programming mode.................................................. 4-10
1.6 Operating modes ........................................................... 4-10
Selecting or activating operating modes .................. 4-11
2. Switching on the machine .......................................... 4-12
2.1 Enabling EMERGENCY STOP...................................... 4-12
2.2 Switching on the machine.............................................. 4-13
3. Switching off the machine.......................................... 4-14
3.1 Switching off the machine in case of emergency or
malfunction.................................................................... 4-14
3.2 Switching off the machine.............................................. 4-14
4. Using Online help ........................................................ 4-15
4-2 0BOperation B561EN04.DOC
5. Entering letters ............................................................ 4-15
6. Optoelectronic safety devices.................................... 4-16
6.1 Safety mode................................................................... 4-16
BendGuard mode..................................................... 4-16
Light curtain mode.................................................... 4-18
6.2 Selecting the safety mode............................................. 4-19
6.3 Operating the machine without optoelectronic
safety device.................................................................. 4-19
7. Loading a program...................................................... 4-20
8. Creating a program...................................................... 4-21
8.1 Creating a program manually........................................ 4-21
8.2 Interlinking two programs............................................... 4-22
8.3 Creating a program graphically (2D)
(drawing profile)............................................................. 4-23
9. Modifying the program................................................ 4-26
10. Programming individual bends.................................. 4-26
11. Creating a tool .............................................................. 4-27
12. Program Management ................................................. 4-29
13. Tool data management................................................ 4-31
14. Changing the language............................................... 4-33
15. Setting the program data ............................................ 4-33
16. Switching between MSC and ASV ............................. 4-34
16.1 Switching from ASV to MSC.......................................... 4-35
16.2 Switching from MSC to ASV.......................................... 4-35
16.3 Programming step change............................................. 4-36
17. Bending workpieces.................................................... 4-37
18. Bending workpieces step by step.............................. 4-38
19. Moving axes manually................................................. 4-39
B561EN04.DOC 1BDescription of the operating elements 4-3
1. Description of the operating elements
1.1 Foot switch
The movement of the beam is triggered via the BEAM DOWN foot
switch.
The indicator lamp shows whether the foot switch is active.
1 EMERGENCY STOP impact
button
2 Indicator lamp
3 EMERGENCY-UP foot switch
4 BEAM DOWN foot switch
Foot switch
Fig. 52437
4-4 1BDescription of the operating elements B561EN04.DOC
1.2 Manual operator console (optional)
The movement of the beam is triggered using the manual button or
the BEAM DOWN foot switch.
The indicator lamp shows whether the manual operator console is
active.
1 Indicator lamp
2 EMERGENCY STOP impact
button
3 Manual button
4 BEAM DOWN foot switch
5 EMERGENCY-UP foot switch
Fig. 52438
B561EN04.DOC 1BDescription of the operating elements 4-5
1.3 Operating elements at the switch
cabinet
5
2
3
1
4
1 HYDRAULIC SYSTEM ON
2 HYDRAULIC SYSTEM OFF
3 Key switch (Operating mode
selection)
4 MAIN SWITCH
5 Light on/off (optional)
Operating elements at the switch cabinet
Fig. 52980
4-6 1BDescription of the operating elements B561EN04.DOC
1 HYDRAULIC SYSTEM ON
2 Key switch (operating mode
selection)
3 MAIN SWITCH
4 HYDRAULIC SYSTEM OFF
5 Light on/off (optional)
6 Service switch
7 EMERGENCY STOP impact
button
Operating elements at the switch cabinet (USA)
Fig. 52443
B561EN04.DOC 1BDescription of the operating elements 4-7
Operating elements Description
Switching off the hydraulic system.
Switching on hydraulic system.
No operating mode selected.
Setup mode:
Moving the machine axes manually (using the J OG buttons at the control
system).
Foot operation:
Operating the machine in foot operation (an operator, a foot switch active).
Trigger the stroke via the BEAM DOWN foot switch.
Key switch (operating
mode selection)
Two-foot operation (optional):
Operate the machine with two foot switches (two operators, two foot
switches active).
Trigger the stroke via the BEAM DOWN foot switch.
ROBOT Robot operation (optional):
Operate the machine with a robot or without an optoelectronic safety
device.
!
Protect mode operating mode (optional):
Machine with robot: Switch off the robot and activate the optoelectronic
safety device (BendGuard or light curtain).
Two-hand operation (optional for machine without CE marking):
Operate the machine using the manual operator console (one operator,
a manual operator console active).
Trigger the stroke via the manual operator console.
key switch options
(operating mode
selection options)
Four-hand operation (optional for machine without CE marking):
Operate the machine with two manual operator consoles (two operators,
two manual operator consoles active).
Trigger the stroke using the both the manual operator consoles.
Note
The operating mode of the machine is selected using the key
switch and the appropriate parameters at the control system (see
section 1.6, p. 4-10).
Tab. 4-1
4-8 1BDescription of the operating elements B561EN04.DOC
1.4 Operating elements for the control
system
7
8
9
10
11
12
3
6
4
1
5
2
1 LCD display/screen
2 Softkeys S1 to S8
3 HELP
4 EMERGENCY STOP impact
button
5 Alphanumeric keyboard with
ENTER and RESET
6 Touch Pad
7 END
8 Cursor keys
9 J OG button
10 Operating mode keys
11 START
12 STOP
Operating elements on the control panel
Fig. 52434
B561EN04.DOC 1BDescription of the operating elements 4-9
Operating mode keys
Symbol Name Description
MANUAL OPERATION Program individual bends.
Execute individual bends.
PROGRAMMING MODE Create and edit programs.
Save and load programs
AUTOMATIC MODE Process programs .
STEP-BY-STEP
OPERATION
Execute every bend of a
program individually.
Tab. 4-2
4-10 1BDescription of the operating elements B561EN04.DOC
1.5 User interface structure
Programming mode
Function/Main operation Description
1. Product input Create a program graphically (2D).
2. Product editing Modify a graphical program (2D).
3. Program input Create a program.
4. Program editing Modify a program.
5. Product overview Displaying and loading programs stored in the
machine directory.
6. Save product Loading or saving bending programs (saving
on a data carrier).
7. Upper tools
8. Lower tools
Creating and modifying tools.
Assigning tools with tool numbers.
9. Beam
10. Press table
Display the machine dimensions.
11. Program data Configure general settings (e.g. change the
language).
12. Save tools Loading or saving tool data (saving on a data
carrier).
1.6 Operating modes
The following operating modes are possible:
Foot mode.
Two-foot mode (optional).
Two-hand operation (optional for machine without CE
marking).
Four-hand operation (optional for machine without CE
marking).
Tab. 4-3
B561EN04.DOC 1BDescription of the operating elements 4-11
Selecting or activating operating modes
1. Select MANUAL OPERATION or PROGRAMMING MODE.
2. Enter the desired parameters.
Note
If only one foot switch is connected, the "FD on/off" or "2 FD
on/off" parameters are not displayed.
3. Under "FD on/off" or "2 FD on/off", select the desired foot
switch or manual operator console.
Parameters Value
"FD on/off" Setting for activating the foot switch or the manual operator
console:
0 =Foot switch 1 is active (only one foot switch or one
manual operator console is connected).
1 =Two foot switches or manual operator consoles are
active.
"2 FD on/off" Displays if one or two manual operator consoles are
connected.
Settings for the manual operator console:
00 or 01 =Foot operation (only the foot buttons of the
manual operator console are active).
10 =Two-hand or foot operation (foot button and manual
button are active. Both the manual button and the foot
button BEAM DOWN must be pressed simultaneously.).
11 =Two-hand operation (both the manual button must
be pressed simultaneously).
4. Press ENTER.
5. Setting the key switch for selection of operating modes at the
switch cabinet to the desired operating mode (see section 1.4,
p. 4-8).
Examples:
"FD on/off" =1
"2 FD on/off" =00 (or 01)
Two manual operator consoles are active but
only the foot button is used.
"FD on/off" =1
"2 FD on/off" is not displayed
Two foot switches are connected and active.
Tab. 4-4
Tab. 4-5
4-12 2BSwitching on the machine B561EN04.DOC
2. Switching on the machine
2.1 Enabling EMERGENCY STOP
EMERGENCY STOP functions can be found at the following
locations:
EMERGENCY STOP impact button at the control system.
MAIN SWITCH with EMERGENCY STOP function.
Foot switch with EMERGENCY STOP impact button.
Manual operator console with EMERGENCY STOP impact
button.
Prerequisite
The lateral and rear safety doors on the machine are closed.
The door of the switch cabinet is closed.
Turn the impact button to the right and pull it out.
Turn the MAIN SWITCH to ON.
Turn the impact button to the right and pull it out.
or
Press the EMERGENCY-UP foot button.
Enabling EMERGENCY STOP
at the control system
Enabling EMERGENCY STOP
via the MAIN SWITCH
Enabling the EMERGENCY
STOP at the foot switch
B561EN04.DOC 2BSwitching on the machine 4-13
2.2 Switching on the machine
Prerequisite
The door of the switch cabinet is closed.
EMERGENCY STOP enables.
The lateral and rear safety doors on the machine are closed.
Caution
Collision in case of set up high tools (from a tool height of
220 mm) possible!
Remove upper and lower tools completely.
Caution
Backgauge fingers may collide with loaded tools!
Loaded tools need to match with the currently programmed
positions of the X and R axes.
1. Switch on the MAIN SWITCH on switch cabinet.
The machine control system will start up.
The Failsafe safety check is complete after approx 30 s. The
indicator lamp on the foot switch lights up.
2. Press MANUAL MODE.
3. Press the EMERGENCY-UP foot button.
Beam will move to the upper dead point.
4. Press START on the control system.
All axes with the exception of the Y1/Y2 axis are automatically
referenced.
Note
The traverse path for the springback test of the beam is
50 mm. The tools must be loaded such that this traverse path
is possible.
5. Press the BEAM DOWN foot switch.
The springback test is carried out.
6. Press the BEAM DOWN foot switch.
The BendGuard reference travel is carried out.
7. Press START on the control system.
4-14 3BSwitching off the machine B561EN04.DOC
3. Switching off the machine
3.1 Switching off the machine in case of
emergency or malfunction
Press the EMERGENCY STOP impact button on the foot
switch.
or
Press EMERGENCY STOP on the control system.
or
Turn the MAIN SWITCH on the control cabinet to O.
or
Push the BEAM DOWN foot switch down hard (EMERGENCY
STOP function of the foot switch is triggered by pressing the
foot switch with a force of between 220 N and 350 N).
Note
If the hydraulic system is switched off via EMERGENCY STOP, it
can be switched on again using the EMERGENCY-UP foot switch.
3.2 Switching off the machine
1. Place a protective workpiece between tools.
2. Lower the beam until there is a gap of approx. 7 mm between
the upper tool tip and the surface of the inserted workpiece.
3. Press HYDRAULIC SYSTEM OFF on the switch cabinet.
The hydraulic system will be switched off and all machine
activities stopped.
4. Turn the MAIN SWITCH to 0.
B561EN04.DOC 4BUsing Online help 4-15
4. Using Online help
Online help for operating the control system can be displayed on
the control system of the machine. If a question mark (?) is
displayed at the control systems, help texts are saved.
1. Press ?.
The help text is displayed.
2. Display the previous or the next page of the help using
Previous page (S2) or Next page (S3).
3. Close the help text using End (S7).
5. Entering letters
The control system has one alphanumeric keyboard. Numbers and
letters are given on every key. If letters can also be entered apart
from numbers, the alphanum softkey is active.
Letters can be entered for:
Drawing numbers.
Tools names.
Directory/folder names.
1. Press the key having the desired letter.
The number of the key is displayed.
2. Press alphanum (S6) till the desired letter is displayed.
Example:
1. Press the 4 key.
4 is displayed.
2. Press alphanum (S6).
G is displayed.
3. Press alphanum (S6).
H is displayed.
4-16 6BOptoelectronic safety devices B561EN04.DOC
6. Optoelectronic safety devices
The machine can be equipped with TRUMPF BendGuard or a light
curtain.
Note
Working at a rapid speed >10 mm/s is permitted only when an
optoelectronic safety device is used.
6.1 Safety mode
BendGuard mode
Mode Description
0 "Normal mode" Profile mode:
All three laser beams are active.
Press the BEAM DOWN foot switch.
The beam moves up to the mute point at rapid
speed and then moves further at operating speed
(max. 10 mm/s) automatically.
The beam stops if the laser beam is interrupted during
the rapid traverse.
1 "Specialist
mode"
Nesting mode:
Only the middle laser beam is active.
In the nesting mode, the nesting height (interruption
height) must be specified.
Press the BEAM DOWN foot switch.
The beam moves up to the mute point at rapid
speed and then moves further at working speed
(max. 10 mm/s) automatically.
The beam stops if the laser beam is interrupted during
the rapid traverse.
2 "Transit mode
field"
Operation without optoelectronic safety device:
The safety device is switched off (BendGuard or the light
curtain).
The beam moves at a maximum speed of 10 mm/s
(operating speed).
1. Press the BEAM DOWN foot switch.
The beam moves up to the mute point at rapid
speed and then moves further at working speed
(max. 10 mm/s) automatically.
B561EN04.DOC 6BOptoelectronic safety devices 4-17
Mode Description
3 "Normal mode,
stop at the
transition
point"
Profile mode with stop at the mute point:
All three laser beams are active.
1. Press the BEAM DOWN foot switch.
The beam moves to the mute point and stops.
2. Press the BEAM DOWN foot switch.
The beam moves at operating speed
(max. 10 mm/s).
The beam stops if the laser beam is interrupted during
the rapid traverse.
4 "Specialist
mode, stop at
the transition
point"
Nesting mode with stop at the mute point:
Only the middle laser beam is active.
In the nesting mode, the nesting height (interruption
height) must be specified.
Press the BEAM DOWN foot switch.
The beam moves up to the mute point at rapid
speed and then moves further at working speed
(max. 10 mm/s) automatically.
The beam stops if the laser beam is interrupted during
the rapid traverse.
5 "Transit mode
field, stop at
transition
point"
Operation without optoelectronic safety device with
stop at the mute point:
The safety device is switched off (BendGuard or the light
curtain).
The beam moves at a maximum speed of 10 mm/s
(operating speed).
1. Press the BEAM DOWN foot switch.
The beam moves to the mute point and stops.
2. Press the BEAM DOWN foot switch.
The beam moves at operating speed
(max. 10 mm/s).
Tab. 4-6
4-18 6BOptoelectronic safety devices B561EN04.DOC
Light curtain mode
Mode Description
2 "Transit mode
field"
Operation without optoelectronic safety device:
The safety device is switched off (BendGuard or the light
curtain).
The beam moves at a maximum speed of 10 mm/s
(operating speed).
1. Press the BEAM DOWN foot switch.
The beam moves up to the mute point at rapid
speed and then moves further at working speed
(max. 10 mm/s) automatically.
5 "Transit mode
field, stop at
transition
point"
Operation without optoelectronic safety device with
stop at the mute point:
The safety device is switched off (BendGuard or the light
curtain).
The beam moves at a maximum speed of 10 mm/s
(operating speed).
1. Press the BEAM DOWN foot switch.
The beam moves to the mute point and stops.
2. Press the BEAM DOWN foot switch.
The beam moves at operating speed
(max. 10 mm/s).
6 "Only protect
mode"
Protect mode:
Press the BEAM DOWN foot switch.
The beam moves up to the mute point at rapid
speed and then moves further at working speed
(max. 10 mm/s) automatically.
The beam stops if the light field in rapid traverse is
interrupted.
7 "Single
interruption
mode"
One-cycle mode (with stop at the mute point):
1. Interrupt the light field once and press the BEAM
DOWN foot switch.
The beam moves to the mute point in rapid traverse
and stops.
2. Press the BEAM DOWN foot switch.
The beam moves at operating speed
(max. 10 mm/s).
If the light field with operating speed is interrupted, the
next strole after the bending is automatically started.
8 "Double
interruption
mode"
Two-cycle mode (with stop at the mute point):
1. Interrupt the light field twice and press the BEAM
DOWN foot switch.
The beam moves to the mute point in rapid traverse
and stops.
2. Press the BEAM DOWN foot switch.
The beam moves at operating speed
(max. 10 mm/s).
If the light field with operating speed is interrupted, the
next strole after the bending is automatically started.
B561EN04.DOC 6BOptoelectronic safety devices 4-19
Mode Description
9 "Only protect
mode, stop at
transition
point"
Protect mode with stop at the mute point:
1. Press the BEAM DOWN foot switch.
The beam moves to the mute point in rapid traverse
and stops.
2. Press the BEAM DOWN foot switch.
The beam moves at operating speed
(max. 10 mm/s).
The beam stops if the light field in rapid traverse is
interrupted.
6.2 Selecting the safety mode
1. Select MANUAL OPERATION or PROGRAMMING MODE.
2. Enter the desired parameters.
3. Enter or select the desired safety mode under "SM safety
mode".
BendGuard: 0, 1, 3 or 4 (see section 6.1, p. 4-16).
Light curtain: 6, 7, 8 or 9 (see section 6.1, p. 4-16).
4. Press ENTER.
6.3 Operating the machine without
optoelectronic safety device
On machines without optoelectronic safety devices, modes 2 nd 5
are provided at the user interface. In this mode, the beam moves at
a safe speed (max. 10 mm/s).
1. Select MANUAL OPERATION or PROGRAMMING MODE.
2. Enter the desired parameters.
3. Enter or select the desired safety mode under "SM safety
mode".
2 or 5 (see section 6.1, p. 4-16).
4. Press ENTER.
Tab. 4-7
4-20 7BLoading a program B561EN04.DOC
7. Loading a program
Programs can be loaded from the bending program directory of the
machine.
Note
Bending programs must be saved in the bending program directory
of the machine so that they can be loaded or processed.
1. Press PROGRAMMING MODE.
2. Select "5. Product overview".
The machine directories are displayed. The last opened
directory is always displayed.
3. To select the directory, select local directory (S7).
4. Select the desired directory using Select (S6).
"(Parent)": open the next higher directory.
5. To create a new folder: press Create a subdirectory (S4), enter
the name of the directory and press ENTER.
6. To adapt the display of the bending programs: select View
(S4).
SOFTKEY Description
normal directory (S4) Display bending programs in a list.
Dir expand (S5) Display bending programs in a list with details.
graph dir (S6) Display a graphical preview of the bending programs.
7. To search for a bending program: select Filter (S5).
SOFTKEY Description
Prod. No (S5) Search for the product number of a bending program.
Drawing no. (S6) Search for the drawing number of a bending program.
8. Mark the desired bending program and select it using ENTER.
9. Press End.
The bending program is loaded (PROGRAMMING MODE, AUTO-
MATIC MODE and STEP-BY-STEP OPERATION). A message is
displayed.
Tab. 4-8
Tab. 4-9
B561EN04.DOC 8BCreating a program 4-21
8. Creating a program
Bending programs can be created at the machine in various ways:
Creating a program manually.
Creating a program graphically (drawing a profile).
8.1 Creating a program manually
1. Select PROGRAMMING MODE.
2. Select "3. Program input".
Note
Pay attention to the Online help (see section 4, p. 4-15).
3. Enter or select parameters and confirm with ENTER.
4. To program another bend: press Yes (S4) and repeat step 3.
5. Repeat step 4 until all the desired bends are programmed.
6. Press No (S5).
7. To close the program: press End.
8. Enter the "Product number PN" and "Drawing number DN" and
confirm with ENTER.
The program is created and loaded (AUTOMATIC MODE).
4-22 8BCreating a program B561EN04.DOC
8.2 Interlinking two programs
Two existing programs can be interlinked. They are consecutively
processed in automatic mode.
1. Select PROGRAMMING MODE.
2. Load a program that is to be linked with another program
(see section 7, p. 4-20).
3. Select "4. Program editing".
Note
Pay attention to the Online help (see section 4, p. 4-15).
4. Under "CN linking", enter the product number of the program
with which this one is to be linked and confirm with ENTER.
5. Press End.
The programs are interlinked.
B561EN04.DOC 8BCreating a program 4-23
8.3 Creating a program graphically (2D)
(drawing profile)
Simple profiles can be graphically drawn and programmed at the
machine. The bending sequence can be calculated and adapted.
1. Select PROGRAMMING MODE.
2. Select the 1. Product input.
3. Enter the parameter and confirm with ENTER.
"Product number".
"Drawing number" (drawing number can also comprise
letters (see section 5, p. 4-15)).
4. Enter the parameter and confirm with ENTER.
Parameter Description
"Thickness"
Enter the sheet thickness.
"Material"
Enter the material number or select a material from
the list.
"Length"
Enter the bend length.
"Dimensions"
Select the inner and outer dimensions.
The first segment of the profile is displayed.
The value to be entered is displayed in the information cell
below.
Note
The currently active segment of the profile is marked with a
circle.
Segments can be marked using cursor keys.
5. Enter the length of the segment and confirm with ENTER.
6. Enter the angle and confirm with ENTER.
7. Repeat steps 5 to 6 until all the segments of the profile have
been drawn.
8. To delete a marked segment: press Delete (S1).
9. To draw a round bending: press Round bending (S2).
Enter the angle and confirm with ENTER.
Enter the radius and confirm with ENTER.
Enter the number of segment and confirm with ENTER.
Creating program
Tab. 4-10
Drawing the profile
Deleting segments
Drawing round bending
4-24 8BCreating a program B561EN04.DOC
10. TO modify the program data subsequently: press Modify data
(S3).
Modify data.
Confirm with ENTER.
Press End.
Note
Machine parts and tools must be programmed (graphical).
11. Select Bending sequences (S5).
Enter or select "Lower tool" and confirm with ENTER.
Enter the number of the "Beam" and confirm with ENTER.
Enter or select "Upper tool" and confirm with ENTER.
The profile with tool is displayed.
The last possible bending is displayed. Other options are
marked with a circle.
12. Adjust the bending sequence.
SOFTKEY Description
Select other bend as the
last bend:
Select the bend with the cursor keys and confirm
with ENTER.
Unbending (S1) Display the previous bend.
All bending lines are marked with a circle.
Bending (S2) Display the next bend.
All bending lines are marked with a circle.
Finger displacement
(S3)
Displace the gauge finger.
Rotation (S4) Rotate bending part.
Lock on/off (S5) Switch the collision check on or off.
Rake (S6) Calculate the bending sequence automatically.
Saving (S7) Save the bending sequence.
The effective length of the profile is displayed.
13. Press Next>> (S8).
Modifying data subsequently
Calculate bending sequence
Tab. 4-11
B561EN04.DOC 8BCreating a program 4-25
14. To display a graphical overview of the bending sequence:
press Bending sequence (S1).
SOFTKEY Description
Lock on/off (S4) Switch the collision check on or off.
The information cell on the screen displays
whether the collision check is switched on or off.
Jumping bend (S5) Replacing the bending sequence.
1. Press Jumping bend. (S5).
2. Mark the bend using the cursor keys.
3. Select the marked bend using ENTER.
4. Mark the second bend using the cursor keys.
5. Confirm with ENTER.
Moving bend (S6) Moving bends.
6. Press Move bend (S6).
7. Mark the bend using the cursor keys.
8. Select the marked bend using ENTER.
9. Move the marked bend to the right using the
cursor keys.
10. Confirm with ENTER.
15. Press End.
16. Press End.
17. Press End.
The program is created.
Tab. 4-12
4-26 9BModifying the program B561EN04.DOC
9. Modifying the program
Existing programs that were created at the machine can be
modified.
1. Select PROGRAMMING MODE.
2. Select "5. Product overview".
3. Load the desired program (see section 7, p. 4-20).
4. To modify a graphically created program: select "2. Product
editing".
5. To modify a manually created program: select "4. Product
editing".
6. Modify parameters.
7. Press End.
10. Programming individual bends
Reduction values are not calculated or used from the table in the
manual mode. All dimensions are used as inner dimensions.
Note
With ? open the control system help. A help text is displayed for
the selected field (see section 4, p. 4-15).
1. Press MANUAL MODE.
2. Enter or select the desired parameters and confirm with
ENTER.
3. To carry out the bending: press START.
B561EN04.DOC 11BCreating a tool 4-27
11. Creating a tool
Up to 99 tools can be stored at the control system, including
30 upper tools and 30 lower tools each.
Tip
To create a new tool: copy an existing tool (from the USB data
carrier, see section 13, p. 4-31) to an empty entry and modify it.
1. Press PROGRAMMING MODE.
2. Select "7. Upper tools" or "8. Lower tools".
3. Mark the empty list entry.
4. Press Modify tool (S8).
5. Enter the dimensions of the tool and confirm with ENTER.
1 Tool height
2 V angle
3 V-opening
4 Radius
Drawing lower tool
Fig. 52850
4-28 11BCreating a tool B561EN04.DOC
6. Enter the dimensions of the tool and confirm with ENTER.
2
1
1 Tool height 2 Tool angle
7. Enter the length and angle of the individual segments of the
tool drawing.
The currently active segment of the tool drawing is marked with
a circle.
8. To delete a marked segment: press Delete line (S3).
9. To draw the tool completely automatically: press auto com-
pletion (S1).
The left side of the tool is completely drawn automatically.
10. Press auto completion (S1).
The right side of the tool is completely drawn automatically.
11. To modify the tool data: press Modify data (S3), modify the
data and confirm with ENTER.
12. To delete the tool drawing completely: press Delete drawing
(S4).
13. Press End.
14. Press End.
15. Press End.
The tool is created.
Drawing upper tool
Fig. 52849
Deleting a segment
Drawing a tool completely
Modifying data
Deleting tools
B561EN04.DOC 12BProgram Management 4-29
12. Program Management
The following program management options are available:
Save the programs from the machine directory on to a USB
data carrier.
Save the programs from the USB data carrier in the machine
directory.
1. Connect the USB data carrier to the control panel.
2. Press PROGRAMMING MODE.
3. Select "6. Save product".
4. To save data from the machine directory on to a USB data
carrier: mark the desired function using the cursor keys.
5. To save data from the USB data carrier in the machine
directory: mark the desired function using the cursor keys.
6. Select Save products (S1).
7. Select the directory in which data is to be loaded or whose
data is to be saved.
Saving data on a USB data
carrier
Fig. 52847
Saving data in the directory
Fig. 52848
4-30 12BProgram Management B561EN04.DOC
8. Select the program.
Softkey Description
all (S3) Mark all programs from this directory.
Backup directory (S4) Create, change, and delete a directory.
Drawing no (S5) Changeover between the following program
selection options:
Product number.
Drawing numbers.
local directory (S7) Display the overview of the folders created in the
machine directory.
normal
directory (S4)
Display bending programs in a
list.
Dir expand
(S5)
Display bending programs in a list
with details.
View (S8)
graph dir (S6) Display a graphical preview of the
bending programs.
9. Press ENTER.
The data is saved either on the USB data carrier or in the
machine directory.
10. To run a backup of the already saved data: press Read
products (S2).
11. Press End.
Tab. 4-13
Reloading saved data
B561EN04.DOC 13BTool data management 4-31
13. Tool data management
The following tool data management options are available:
Save the tool data from the machine directory on to a USB
data carrier.
Save the tool data from the USB data carrier in the machine
directory.
1. Connect the USB data carrier to the control panel.
2. Press PROGRAMMING MODE.
3. Select "12. Save tools".
4. To save data from the machine directory on to a USB data
carrier: mark the desired function using the cursor keys.
5. To save data from the USB data carrier in the machine
directory: mark the desired function using the cursor keys.
6. Press Backup directory (S4) and select the directory in which
data is to be loaded or whose data is to be saved.
7. Select data.
Softkey Description
all (S3) Mark all the data from this directory.
Backup directory (S4) Create, change, and delete a directory.
local directory (S7) Display the overview of the folders created in the
machine directory.
Saving data on a USB data
carrier
Fig. 52845
Saving data in the directory
Fig. 52846
Tab. 4-14
4-32 13BTool data management B561EN04.DOC
8. Select Save tools (S1).
The data is saved either on the USB data carrier or in the
machine directory.
9. To run a backup of the already saved data: press Read tools
(S2).
10. Press End.
Reloading saved data
B561EN04.DOC 14BChanging the language 4-33
14. Changing the language
1. Press PROGRAMMING MODE.
2. Select "11. Program data".
3. Select "Language (LA)" or the enter the number of the desired
language.
4. Select "Language help (HL)" or enter the number of the
desired language.
5. Press End.
6. Press End.
15. Setting the program data
1. Press PROGRAMMING MODE.
2. Select "11. Program data".
Note
Observe the Online help at the control system.
3. Set the program data.
4. Press End.
5. Press End.
Changing the language of the
control system
Modifying the language of the
Online help
4-34 16BSwitching between MSC and ASV B561EN04.DOC
16. Switching between MSC and ASV
Bending programs are processed in automatic mode. The rear stop
can be traversed with two methods:
Manual increment switching (MSC):
To move the backgauge to the next stop position after the
bending, press the BEAM DOWN foot switch. Then trigger
the next stroke.
Automatic Safety Path System (ASV): the backgauge travels
automatically to the next stop position at the end of the
bending operation.
If the target point is located within a defined safety range,
then the backgauge will travel to the stop position from
above with maximum speed. The danger of squeezing and
crushing is avoided by a hinged rear stop finger.
If the start and target points are located outside the defined
safety range, then the backgauge will travel with maximum
speed directly to the stop position.
A
B
V
max
V
max
B
A
V
max
A
B
V
max
A
B
50
5
0
A Start position B End position V
max
Maximum speed
Traversing examples
Note
Fig. 39381
B561EN04.DOC 16BSwitching between MSC and ASV 4-35
If it is not possible to work with the "Automatic Safety Path System"
(ASV), then a corresponding message is displayed on the user
interface. The "Manual increment switching" (MSC) method must
be traversed in such cases.
16.1 Switching from ASV to MSC
1. Press PROGRAMMING MODE.
2. Enter 19 and press ENTER.
3. Enter the "access code" 14753 and press ENTER.
"Machine parameter" is opened.
5. Select "1. General parameters".
6. Use Next page (S2) to select "Sequencer options".
7. Select the parameter "M_OPTION17".
8. Enter 0 and press ENTER.
9. Press End.
9. Press End.
9. Press Next (S5).
The control system reboots.
10. Select "11. Program data".
"Program data" will open.
11. Use Next page (S2) to select the "Production settings".
12. Select the parameter "Between X for Z movement... XS".
13. Enter 50 and press ENTER.
14. Select parameter "Between R for X movement... RS".
15. Enter 50 and press ENTER.
16. Press End.
16.2 Switching from MSC to ASV
1. Press PROGRAMMING MODE.
2. Enter 19 and press ENTER.
3. Enter the "access code" 14753 and press ENTER.
"Machine parameter" is opened.
5. Select "1. General parameters".
6. Use Next page (S2) to select "Sequencer options".
4-36 16BSwitching between MSC and ASV B561EN04.DOC
7. Select the parameter "M_OPTION17".
8. Enter 1 and press ENTER.
9. Press End.
9. Press End.
9. Press Next (S5).
The control system reboots.
10. Select "11. Program data".
"Program data" will open.
11. Use Next page (S2) to select the "Production settings".
12. Select the parameter "Between X for Z movement... XS".
13. Enter 0 and press ENTER.
14. Select parameter "Between R for X movement... RS".
15. Enter 0 and press ENTER.
16. Press End.
16.3 Programming step change
If ASV is active, various step change options can be differentiated
(step change =moving the backgauge to the next position).
1. Select MANUAL MODE or PROGRAMMING MODE.
2. Enter the desired parameters.
Note
Pay attention to the Online help (see section 4, p. 4-15).
3. Enter or select the desired step change method under "Code
CX".
4. Press ENTER.
B561EN04.DOC 17BBending workpieces 4-37
17. Bending workpieces
Information
The backgauge traverses automatically at the end of the
bending operation when working with ASV (Automatic Safety
Travel Speed System).
If ASV is not possible, a corresponding message is
displayed on the user interface. Traversing must be done
with "Manual increment switching" in such cases (see
section 16.1, p. 4-35).
When working with MSC (manual increment switching), the
BEAM DOWN foot switch must be pressed after each bend to
move the backgauge.
Prerequisite
The desired bending part has been loaded (see section 7,
p. 4-20).
1. Press AUTOMATIC MODE.
2. Select the desired operation mode at the operation mode
selection key switch.
3. Press START.
4. Place workpiece between upper and lower tool and bring it
against the backgauge.
5. To move the beam downwards: press the BEAM DOWN foot
switch.
4-38 18BBending workpieces step by step B561EN04.DOC
18. Bending workpieces step by step
Every bend is individually executed in the step-by-step operation.
Every bend must be actively started using the BEAM DOWN foot
switch
Prerequisite
The desired bending part has been loaded (see section 7, p. 4-
20).
1. Press STEP-BY-STEP OPERATION.
2. Select the desired operation mode at the operation mode
selection key switch.
3. To select a bend: select the desired bend using Previous bend
(S1) or Next bend (S2).
4. Press START.
5. Place workpiece between upper and lower tool and bring it
against the backgauge.
6. To move the beam downwards: press the BEAM DOWN foot
switch.
A program bending is carried out. The beam stops.
The control system switches to STOPP.
Depending on the program data setting, either the current bend
is retained or the next bend is displayed (Programming
mode>7. Program data> Production settings> Auto Bending
change (step) CS).
7. To carry out more bendings: repeat steps 3 to 6.
B561EN04.DOC 19BMoving axes manually 4-39
19. Moving axes manually
The machine axes can be shifted manually with the J OG buttons.
1. Set the key switch for operation mode selection to "Setup
mode" (see section 1.3, p. 4-5).
2. Press MANUAL MODE, AUTOMATIC MODE or STEP-BY-
STEP OPERATION.
3. Press Manual Pos (S7).
4. Select the desired axis.
5. Move the axis with the J OG buttons.
Tip
To move the selected axis faster, press the J OG button -+.
6. Press End.
4-40 19BMoving axes manually B561EN04.DOC
B561EN05.DOC 0BSetting work 5-1
Chapter 5
Setting work
1. Adjusting gauge finger.................................................. 5-3
1.1 Adjusting gauge finger for manual Z axis........................ 5-3
2. Setting up tools.............................................................. 5-4
2.1 Loading upper tools ......................................................... 5-4
Loading upper tools with manual tool clamping......... 5-5
Loading upper tools with TRUMPF Quick Clamp
(optional)..................................................................... 5-6
Loading upper tools in case of pneumatic tool
clamping (optional) ..................................................... 5-8
2.2 Loading lower tools.......................................................... 5-9
Loading lower tools with manual tool clamping.......... 5-9
Loading lower tools in case of pneumatic tool
clamping (optional) ................................................... 5-10
3. Segments of the upper tool holder ............................ 5-11
3.1 Dismantling segment..................................................... 5-11
3.2 Installing segment.......................................................... 5-12
5-2 0BSetting work B561EN05.DOC
4. Optoelectronic safety devices.................................... 5-13
4.1 TRUMPF BendGuard.................................................... 5-13
Dismantling BendGuard........................................... 5-13
Installing BendGuard................................................ 5-14
Setting the height of BendGuard.............................. 5-16
Checking the laser beam.......................................... 5-17
4.2 Light curtain................................................................... 5-18
Aligning transmitter and receiver.............................. 5-18
Checking the function of the light curtain................. 5-19
B561EN05.DOC 1BAdjusting gauge finger 5-3
1. Adjusting gauge finger
All CNC-controlled axes can be programmed freely using the
control system (see Chapter: Control system instruction manual").
With the optional CNC-controlled Z1-/Z2 axis, adjustment of the
gauge fingers is carried out automatically.
1.1 Adjusting gauge finger for manual
Z axis
Prerequisite
The machine is ready for operation.
Press MANUAL OPERATION or PROGRAMMING OPERATION.
Press Machine function (S8).
1. Press Finger adjustment ON (S7).
The beam moves upward.
"Backgauge finger adjustment active" appears on the screen.
2. Press START.
The backgauge moves towards the front to a safe position in
front of the tool level.
3. Position gauge fingers.
4. Press Finger adjustment OFF (S7).
5. Press START on the control system.
The backgauge travels back to its programmed position.
5-4 2BSetting up tools B561EN05.DOC
2. Setting up tools
The TruBend Series 3000 press brakes are equipped with manual,
pneumatic or quick clamping.
2.1 Loading upper tools
Warning
Inadequately fixed upper tools can fall out of the clamps!
Risk of injury.
Check the fastening of the upper tools after tool
replacements.
Warning
There is a risk of objects or body parts being caught
between the upper tool and the machine frame.
Do not load upper tools laterally over the upper tool holder.
B561EN05.DOC 2BSetting up tools 5-5
Loading upper tools with manual tool
clamping
Prerequisite
The machine is ready for operation.
The back stops and clamping surfaces of the tools are clean.
Additional equipment, tools, material
Size 8 Allen key.
1
1
1 Socket head screws
1. Open the beam with the EMERGENCY-UP foot switch so that
tools can be easily positioned.
2. Loosen the hexagonal socket screws on the tool clamping.
3. To load upper tools:
Insert the upper tool vertically with Safety-Click and
position it.
or
If BendGuard is loaded: raise BendGuard until it stops and
locks into place.
Push in the upper tool from the side without Safety-Click
and position it.
Raise BendGuard once again and then lower it manually.
4. Tighten the hexagonal socket screws and fix the upper tool.
Clamping upper tools
Fig. 52973
5-6 2BSetting up tools B561EN05.DOC
Note
The upper tool holder for TRUMPF tools is self-centering.
5. Upper tools that are not self-centering must be aligned by
means of an idle stroke before the first bending operation.
Loading upper tools with TRUMPF
Quick Clamp (optional)
Prerequisite
The machine is ready for operation.
The back stops and clamping surfaces of the tools are clean.
TRUMPF Quick Clamp
1. Open the beam with the EMERGENCY-UP foot switch so that
tools can be easily positioned.
2. Open the tool clamping using the quick clamping lever.
Centering upper tools
Clamping upper tools
Fig. 52439
B561EN05.DOC 2BSetting up tools 5-7
3. To load upper tools:
Insert the upper tool vertically with Safety-Click and
position it.
or
If BendGuard is loaded: raise BendGuard until it stops and
locks into place.
Push in the upper tool from the side without Safety-Click
and position it.
Raise BendGuard once again and then lower it manually.
4. Close the tool clamping using the quick clamping lever.
Note
The upper tool holder for TRUMPF tools is self-centering.
5. Upper tools that are not self-centering must be aligned by
means of an idle stroke before the first bending operation.
Centering upper tools
5-8 2BSetting up tools B561EN05.DOC
Loading upper tools in case of pneumatic
tool clamping (optional)
Pneumatic upper tool clamping, uniform
1. Open the beam with the EMERGENCY-UP foot switch so that
tools can be easily positioned.
2. To open the tool clamping: press Loosen OW (S5).
3. To load upper tools:
Insert the upper tool vertically with Safety-Click and
position it.
or
If BendGuard is loaded: raise BendGuard until it stops and
locks into place.
Push in the upper tool from the side without Safety-Click
and position it.
Raise BendGuard once again and then lower it manually.
4. To close the tool clamping: press Clamp OW (S5).
Note
The upper tool holder for TRUMPF tools is self-centering.
5. Upper tools that are not self-centering must be aligned by
means of an idle stroke before the first bending operation.
Clamping upper tools
Fig. 50411
Centering upper tools
B561EN05.DOC 2BSetting up tools 5-9
2.2 Loading lower tools
Warning
Lower tools are heavy and can slip out of your hands.
Danger of crushing.
Wear safety shoes.
Note
There is a notch on one side of symmetrical TRUMPF lower tools.
This notch must be visible on the front side after loading the tools.
Loading lower tools with manual tool
clamping
Prerequisite
The machine is ready for operation.
The back stops and clamping surfaces of the tools are clean.
Additional equipment, tools, material
Size 8 Allen key.
1 1 1
1 Socket head screws
Fig. 52974
5-10 2BSetting up tools B561EN05.DOC
1. Open the beam with the EMERGENCY-UP foot switch so that
tools can be easily positioned.
2. Loosen the hexagonal socket screws at the terminal strip.
3 Insert and position lower tools vertically.
4. Re-tighten the hexagonal socket screws and fix the lower tools.
Loading lower tools in case of pneumatic
tool clamping (optional)
1. Open the beam with the EMERGENCY-UP foot switch so that
tools can be easily positioned.
2. To open the tool clamping: press Loosen UW (S6).
3 Insert and position lower tools vertically.
4. To close the tool clamping: press Clamp UW (S6).
B561EN05.DOC 3BSegments of the upper tool holder 5-11
3. Segments of the upper tool holder
Note
The segments of the upper tool holder are aligned to each other. If
the tools are not always installed in the same sequence, it can lead
to inaccuracies when bending.
Warning
Segments of clamping are heavy and can slip out of your
hands.
Danger of crushing.
Wear safety shoes.
3.1 Dismantling segment
Additional equipment, tools, material
Size 6 Allen key.
1 1
2
1 Socket head screws 2 Distance between the segments
Segments of pneumatic upper tool holder
1. Loosen hexagonal socket screws (1) and when doing so, hold
the segment of the clamping.
2. Remove the segment in a downward direction.
3. Tighten the hexagonal socket screws.
Tip
Number the segments of the upper tool clamping on the rear side
and position of the segment on the beam.
Fig. 52851
5-12 3BSegments of the upper tool holder B561EN05.DOC
3.2 Installing segment
Additional equipment, tools, material
Size 6 Allen key.
1 1
2
1 Socket head screws 2 Distance between the segments
Segments of pneumatic upper tool holder
1. Loosen the hexagonal socket screws.
2. Insert the segment from below and hold it.
3. Tighten the hexagonal socket screws.
Tip
Number the segments of the upper tool clamping on the rear side
and position of the segment on the beam.
Fig. 52851
B561EN05.DOC 4BOptoelectronic safety devices 5-13
4. Optoelectronic safety devices
4.1 TRUMPF BendGuard
Dismantling BendGuard
Note
When the BendGuard is removed, the beam can only be moved at
working speed (max. 10 mm/s).
Additional equipment, tools, material
Size 5 Allen key.
Size 6 Allen key.
1
2
3
1 Plugs for BendGuard
2 Hexagonal socket screw (6)
3 Hexagonal socket screw (5) of
the cover plate
Fig. 52853
5-14 4BOptoelectronic safety devices B561EN05.DOC
1. Move beam to mute point.
2. Disconnect the plug (1).
3. Loosen the hexagonal socket screw (3).
4. Remove the cover plate.
5. Loosen the hexagonal socket screws (2).
6. Remove BendGuard.
Installing BendGuard
Additional equipment, tools, material
Size 5 Allen key.
Size 6 Allen key.
1
2
3
1 Plugs for BendGuard
2 Hexagonal socket screw (6)
3 Hexagonal socket screw (5) of
the cover plate
Fig. 52853
B561EN05.DOC 4BOptoelectronic safety devices 5-15
1. Switch off the machine in the correct manner and switch off the
MAIN SWITCH.
2. Position BendGuard and align it vertically.
3. Tighten hexagonal socket screw (2).
4. Connect the plug (1).
Note
Ensure that the position of the BendGuard cable is correct.
5. Mount the cover plate and tighten the hexagonal socket screw
(3).
Connecting BendGuard to
the machine
5-16 4BOptoelectronic safety devices B561EN05.DOC
Setting the height of BendGuard
BendGuard magnetic bolts
1. Read the workpiece height on the used upper tool:
1
1 Tool height
Upper tool
2. Fix BendGuard using magnetic bolts.
Fig. 43075
Fig. 30199
B561EN05.DOC 4BOptoelectronic safety devices 5-17
Checking the laser beam
Warning
If the laser beam B is above 14 mm, the machine no longer
stops within the braking distance!
Amputation of body parts possible.
Readjusting the laser beam.
A check must be made after each tool change and at regular
intervals to determine whether or not laser light B is positioned
14 mm below the upper tool tip:
Checking the laser beam
Note
Laser light B must be positioned precisely 14 mm (0.5 mm)
underneath the upper tool tip.
Hold the platelet centered under the tool tip.
The red laser light B is positioned 14 mm under the upper tool tip.
This position test must be correct for the entire length of the
machine.
Fig. 35726
5-18 4BOptoelectronic safety devices B561EN05.DOC
4.2 Light curtain
Aligning transmitter and receiver
The transmitter and receiver must be in exact alignment to one
another. If they are not in exact alignment, the machine stops. The
following problems can occur:
It can cause an interruption if the light from the transmitter
does not completely hit the receiver (too little light).
If barely sufficient light hits the receiver, minimal contamination
can lead to interruptions.
The problems mentioned above trigger a machine stop. To avoid
this, it is necessary to align the transmitter and receiver exactly.
The transmitter and receiver are fastened with fixed holding
brackets, which specify the alignment extensively.
Note
When the laser alignment aid AR 60 is used, proceed according to
the description included with the device.
1. Align transmitter and receiver to each other.
2. Switch on power supply.
3. Swivel transmitter forwards until the red LED on the receiver
lights up and the green LED goes out.
4. Note the position of the transmitter.
5. Swivel transmitter back until the red LED on the receiver lights
up and the green LED goes out.
6. Note the position of the transmitter.
7. Fix the transmitter in the center of the swiveling range
(positions from steps 4 and 6).
8. Swivel the receiver forwards until the red LED lights up and the
green LED goes out.
9. Note the position of the receiver.
10. Swivel the receiver back until the red LED lights up and the
green LED goes out.
11. Note the position of the receiver.
12. Fix the receiver in the center of the swiveling range (positions
from steps 9 and 11).
Aligning the transmitter
Aligning the receiver
B561EN05.DOC 4BOptoelectronic safety devices 5-19
Checking the function of the light curtain
Warning
Even if the red LED does not light up, the beam moves down
in rapid speed!
If when checking function the green or yellow transmitter
LEDs only at one point, work may not be continued with the
machine.
Note
The light curtain must be checked daily before starting the
production.
Move the supplied test bar within the field of protection
markings in the middle between transmitter and receiver slowly
through the whole field of protection.
The red LED on the receiver lights up.
5-20 4BOptoelectronic safety devices B561EN05.DOC
B561EN06.DOC 0BMaintenance 6-1
Chapter 6
Maintenance
1. General guidelines......................................................... 6-3
2. Maintenance overview................................................... 6-4
3. Lubrication ..................................................................... 6-5
3.1 Overview.......................................................................... 6-5
3.2 Maintenance instructions................................................. 6-7
Hydraulic system........................................................ 6-7
X axis guide rail ........................................................ 6-12
R axis guide rail ........................................................ 6-13
Ballscrew.................................................................. 6-14
Z axis guide rail......................................................... 6-15
4. Hydraulic components ................................................ 6-16
4.1 Overview........................................................................ 6-16
4.2 Maintenance instructions............................................... 6-17
Hydraulic hose lines ................................................. 6-17
6-2 0BMaintenance B561EN06.DOC
5. Pneumatic components .............................................. 6-18
5.1 Overview........................................................................ 6-18
5.2 Maintenance instructions............................................... 6-19
Compressed air filter with water separator............... 6-19
6. Mechanical components ............................................. 6-21
6.1 Overview........................................................................ 6-21
6.2 Maintenance instructions............................................... 6-22
Upper and lower tool holders.................................... 6-22
Z axis guide rail......................................................... 6-24
Z axis toothed belt (with optional 4-axes
backgauge)............................................................... 6-24
X axis fixed stop ....................................................... 6-25
7. Electrical components ................................................ 6-26
7.1 Overview........................................................................ 6-26
7.2 Maintenance instructions............................................... 6-28
Safety switch of the protective covers...................... 6-28
Failsafe control system PCSS-F............................... 6-29
Electrical cables........................................................ 6-30
Switch cabinet........................................................... 6-31
Optoelectronic safety device.................................... 6-31
B561EN06.DOC 1BGeneral guidelines 6-3
1. General guidelines
Appropriate maintenance is a prerequisite for maintaining the
quality of the machine. It prevents operational malfunctions and
their consequences.
Danger
Risk of injury when carrying out maintenance work when the
machine is switched on.
Unless expressly stated otherwise:
Switch off the MAIN SWITCH.
Lock the MAIN SWITCH.
Remove the key.
Strictly observe the safety regulations.
Clean the entire system at regular intervals.
Brush off large particles of dirt or remove them with an
industrial vacuum cleaner.
Lightly grease the cylinder pistons when cleaning the machine
and whenever whistling noises occur:
Remove the cover of the cylinders.
Move the beam to the lower stop position.
Lightly grease the cylinder pistons. Suitable grease can be
obtained from TRUMPF.
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.
Use only lint-free cleaning cloths and low-viscosity spindle oil
("scavenge oil") to clean oil chambers and lubricating points.
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 properly.
Notes on cleaning
Notes on lubrication
6-4 2BMaintenance overview B561EN06.DOC
2. Maintenance overview
Interval
(operating
hours)
Maintenance point Maintenance work Page
8 Hydraulic oil level indicator Checking the oil level 6-7
8 Hydraulic oil filter Checking for text message on the control
system display
6-7
8 Safety switch on protective covers Checking functions 6-28
40 Upper and lower tool holders Cleaning 6-22
40 Guide rail for gauge finger displacement
(Z axis)
Cleaning 6-24
40 Pneumatic maintenance unit Draining condensation water 6-19
500 Hydraulic oil filter Changing the oil filter 6-8
500 X axis guide rail Lubricating 6-12
500 R axis guide rail Lubricating 6-13
500 Z axis guide rail Lubricating 6-15
500 Ballscrew Lubricating 6-14
500 Toothed belt of Z axis
(with optional 4-axis backgauge)
Checking 6-24
500 Fixed stop of X axis Checking 6-25
500 Upper and lower tool holders Check the distance between the segments of
the tool clamping and adjust it if required
6-23
1000 Electrical cables Checking 6-30
1000 Switch cabinet Cleaning, checking 6-31
2000 Hydraulic hoses Checking 6-17
5000 Hydraulic oil filter Changing oil filter, analyzing oil 6-8
20000 Hydraulic system Changing oil 6-10
Every three
years
Failsafe control system Replacing battery 6-29
If required Optoelectronic safety device Cleaning the transmitter and receiver 6-31
If required Pneumatic maintenance unit Cleaning the compressed air filter 6-20
For single-shift operation:
eight operating hours Daily
40 operating hours Weekly
500 operating hours Three months
1000 operating hours Six months
2000 operating hours Annually
5000 operating hours After 2.5 years
20000 operating hours After 10 years
Every three years After 3 years, regardless of the
number of operating hours
Tab. 6-1
Tab. 6-2
B561EN06.DOC 3BLubrication 6-5
3. Lubrication
3.1 Overview
h
500
2 1 4 3
1 R axis recirculating ball unit
2 Ballscrew
3 Z axis recirculating ball unit 4 X axis recirculating ball unit
Lubrication chart for 2-, 4- and 5-axis backgauges
h
Specification of the
lubrication intervals in
operating hours
Monitor oil level and,
if necessary, top up to
required level
Reading the
maintenance
instructions
Checking the oil level
Lubrication with
a grease gun
Emptying the container
Lubrication with oil can
or spray can
Replacing the contents
of the container
Fig. 43043
Tab. 6-3
6-6 3BLubrication B561EN06.DOC
Note
Established equivalent lubricants from other manufacturers can
also be used. However, different types of oil may not be mixed.
Caution
Ladders leaning against the machine can easily fall over!
For maintenance work that requires climbing equipment, use
a stepladder.
Warning
In case of oil replacement and other maintenance activities
that are carried out immediately after machine operation, the
temperature of the oil can be up to 80C.
Danger of burns
Implement suitable safety measures.
Lubrication point Quantit
y [l]
Recommended lubricant Identification Viscosity,
consistency
Hydraulic system
3066
3120
3180
100
200
250
Aral Vitam DE 46
BP Energol HLP-D 46
CASTROL Hyspin AWH-M 46
(initial filling)
Elf Elfolna HMD 46
ESSO HLPD oil 46
Mobil hydraulic oil HLPD 46
SHELL Tellus Oil 46
CL, HL, HLP,
HLPD
ISO VG 46
Ballscrew SHELL Alvania EP2
MOBIL Mobilux-EP2
KP2K-20 NLGI 2
X axis recirculating
ball unit
SHELL Alvania EP2
MOBIL Mobilux-EP2
KP2K-20 NLGI 2
R axis recirculating
ball unit
SHELL Alvania EP2
MOBIL Mobilux-EP2
KP2K-20 NLGI 2
Z axis recirculating
ball unit
SHELL Alvania EP2
MOBIL Mobilux-EP2
KP2K-20 NLGI 2
Tab. 6-4
B561EN06.DOC 3BLubrication 6-7
3.2 Maintenance instructions
Hydraulic system
(see Overview, p. 6-5)
Maintenance interval: 8 operating hours.
1
1
1 Marking min/max
Oil level indicator
1. Press HYDRAULIC SYSTEM ON.
The hydraulic pump of the machine is switched on.
2. Check oil level.
The oil level must be between the upper and lower marks of the oil
level indicator.
Maintenance interval: eight operating hours.
Check for text message on the control system display.
The oil filter must be replaced if a text message appears on the
control system display.
Checking the oil level
Fig. 52978
Checking the contamination
of the oil filter
6-8 3BLubrication B561EN06.DOC
Maintenance interval: 5000 operating hours.
Information
The oil filter needs to be changed more frequently with a new
machine.
First oil filter replacement after 500 operating hours.
Second oil filter replacement after a total of 2500 operating
hours.
Third oil filter replacement after a total of 5000 operating
hours.
The oil filter must be replaced before time if a message to that
effect is displayed at the control system.
1
1 Hydraulic oil filter
Hydraulic oil pump with a hydraulic filter (from below)
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Change the filter element of the hydraulic oil filter.
3. Check the filter housing.
4. Check the bypass valve.
Changing the oil filter
Fig. 52855
B561EN06.DOC 3BLubrication 6-9
Maintenance interval: 5000 operating hours.
1. Change oil filter (see above).
2. 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.
Warning
If the water content is >1000 ppm, then damage to compo-
nents has probably already been caused!
Corrosion of the machine
Contact TRUMPF technical customer service.
3. The hydraulic oil must be changed if the analysis indicates at
least one of the following values (see below):
TAN (Total Acid Number) >2.5.
Viscosity <41.4 mm
2
/s or >50.6 mm
2
/s for ISO VG 46.
Water content >500 ppm.
Value Explanation/effect
TAN
(Total Acid Number)
Oil ages; surface corrosion and deposits possible.
Viscosity Significant deviations in viscosity are a sign of severe
contamination and foul oil.
Water content The vapor pressure of water is significantly higher than
that of oil.
It can cause cavitation (vapor bubbles are created at
low pressure before the water condenses suddenly
(when pressure is increased)).
Analyzing the hydraulic oil
Tab. 6-5
6-10 3BLubrication B561EN06.DOC
Maintenance interval: 20000 operating hours.
If the analysis of the hydraulic oil shows non-permissible values,
then the hydraulic oil needs to be changed earlier.
Additional equipment, tools, material
Oil pump with integrated filter (optional, available from
TRUMPF).
Drilling machine.
Filter with a pore size of 3 m.
Information
Observe the applicable national safety guidelines and accident
prevention regulations (see "Safety" chapter).
Only use the same type of oil as before for topping up.
Replace the oil filter every time the hydraulic oil is changed.
Caution
Unfiltered oil destroys the hydraulic system!
Warranty claims are rendered void.
Use filters with 3 m pores to prefilter new oil.
1
1 Drain cock
Drain cock at the oil tank (from below)
Changing the hydraulic oil
Fig. 52854
B561EN06.DOC 3BLubrication 6-11
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Connect tube to drain cock.
3. Drain waste oil into a container.
4. Pump new hydraulic oil from the oil drum into the oil tank of the
machine. When pumping the oil, pre-filter it using a filter with a
pore size of 3 m.
5. Change the oil filter (see page 6-5).
6. Switch on machine and the hydraulic system.
7. Program individual bends in the MANUAL MODE.
8. Press START.
9. Carry out a 30 min bending stroke and monitor the process.
10. Check the oil level and top up the oil if necessary.
6-12 3BLubrication B561EN06.DOC
X axis guide rail
(see Overview, p. 6-5)
Maintenance interval: 500 operating hours.
1
1 Grease nipples
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Lubricate the grease nipples (1) using a grease gun.
3. Switch on the machine.
4. Move the X axis by 30 mm.
5. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
6. Repeat steps 2 to 4 three times.
Grease nipple lubricated in 4 different axis positions.
Lubricate the grease nipple
Fig. 43044
B561EN06.DOC 3BLubrication 6-13
R axis guide rail
(see Overview, p. 6-5)
Maintenance interval: 500 operating hours.
1 1
1 Grease nipples
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Remove the cover plate on the front side of the backgauge by
sliding it upwards.
3. Lubricate the grease nipple (1) using a grease gun.
4. Switch on the machine.
5. Move the R axis by 30 mm.
6. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
7. Repeat steps 3 to 5 three times.
Grease nipple lubricated in 4 different axis positions.
Lubricate the grease nipple
Fig. 52859
6-14 3BLubrication B561EN06.DOC
Ballscrew
(see Overview, p. 6-5)
Maintenance interval: 500 operating hours.
1 Grease nipples
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Remove the cover plate on the front side of the backgauge by
sliding it upwards.
3. Lubricate the grease nipple (1) using a grease gun.
4. Switch on the machine.
5. Move the R axis by 30 mm.
6. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
7. Repeat steps 3 to 5 three times.
Grease nipple lubricated in 4 different axis positions.
Lubricate the grease nipple
Fig. 43045
B561EN06.DOC 3BLubrication 6-15
Z axis guide rail
(see Overview, p. 6-5)
Maintenance interval: 500 operating hours.
1
1
1 Grease nipples
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Lubricate the grease nipples (1) using a grease gun.
3. Switch on the machine.
4. Move the Z axis by 30 mm.
5. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
6. Repeat steps 2 to 4 three times.
Grease nipple lubricated in 4 different axis positions.
Lubricate the grease nipple
Fig. 52852
6-16 4BHydraulic components B561EN06.DOC
4. Hydraulic components
4.1 Overview
1
1 Hydraulic system hoses
Fig. 52856
B561EN06.DOC 4BHydraulic components 6-17
4.2 Maintenance instructions
Hydraulic hose lines
(see Overview page 6-16)
Maintenance interval: 2000 operating hours.
Information
The hydraulic hose lines should be checked by an expert to
assure safe operating condition. They should also be checked
before the machine is put into service for the first time.
A specialist is someone who has completed an appropriate
training course (e.g. TRUMPF training course "Certificate of
qualification - Pressure vessel regulations").
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.
Publisher:
Commercial and industrial employer's liability insurance
association membership corporation P. O. box 20 52
53757 St. Augustin
Sales:
Carl Heymanns Verlag KG
Luxemburger Str. 449
50939 Kln
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Check the hydraulic hoses for defects. Possible defects:
Damage on the outer layer extending to the inner lining
(e.g. abrasions, cuts, or tears).
Brittleness of the outer layer (crack formation of the hose
material).
Deformations not corresponding to the natural form of the
hose in a depressurized or a pressurized state or when
bent (separation of layers, blistering, crushed or bent
areas).
Leaks
Installation requirements not observed.
The hose dislodging itself from the fittings.
Damage or distortion of the fittings which diminishes
function and stability of the fittings or impairs the
connection between hose and fittings.
Corrosion of the fittings that impairs the functionality and
stability.
Expired storage time or service life (according to ZH 1/74).
Checking the hoses
6-18 5BPneumatic components B561EN06.DOC
5. Pneumatic components
5.1 Overview
1
1 Compressed air filter with water separator
Note
A pneumatic system is available only if the machine has a
pneumatic tool clamping.
Fig. 52975
B561EN06.DOC 5BPneumatic components 6-19
5.2 Maintenance instructions
Compressed air filter with water separator
(see Overview page 6-16)
Maintenance interval: 40 operating hours.
The pressure filter with water separator removes moisture from the
air as well as hard particles such as dust, scale and rust.
1
1 Compressed air filter with water
separator
1
2
3
1 Filter cartridge
2 Sight glass
3 Drain
Draining condensation water
Fig. 52976
Fig. 2109
6-20 5BPneumatic components B561EN06.DOC
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Open the drain (3).
3. Position the tilted drain piece at the lower end of the sight glass
(2).
Condensation water drains off.
Maintenance interval: as needed.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Close air supply.
3. Unscrew the sight glass (2).
4. Clean the sight glass (2) with water.
5. Dismantle filter cartridge (1).
6. Wash the filter cartridge (1) with kerosene or gasoline and blow
it dry from the inside to the outside with compressed air.
7. Install filter cartridge (1).
8. Install sight glass (2).
Note
If the filter cartridge is very contaminated, replace it (mat. no.
1279210).
Cleaning the compressed
air filter
B561EN06.DOC 6BMechanical components 6-21
6. Mechanical components
6.1 Overview
1 2 3 4 5
1 Tool holder for upper tool
2 Tool holder for lower tool
3 Z axis toothed belt
4 Z axis guide rail
5 Fixed stop of X axis
Fig. 52857
6-22 6BMechanical components B561EN06.DOC
6.2 Maintenance instructions
Upper and lower tool holders
(see "Overview", page 6-21)
Maintenance interval: 40 operating hours.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Clean the upper and lower tool holders with a lightly oiled cloth.
Cleaning the tool holder
B561EN06.DOC 6BMechanical components 6-23
Maintenance interval: 500 operating hours.
Additional equipment, tools, material
Size 6 Allen key.
1 1
2
1 Socket head screws 2 Distance between the segments
Segments of pneumatic upper tool holder
Note
The distance between the individual segments of the upper tool
holder should always be 2 mm.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Check the distance between the individual segments of the
upper tool holder (2).
Note
If the distance is more than or less than 2 mm, adjust it.
3. Unscrew the hexagonal socket screws (1x) of the segment.
4. Shift the segment.
5. Retighten the hexagonal socket screws (1).
Check the distance between
the segments of the tool
clamping and if required,
adjust it
Fig. 52851
6-24 6BMechanical components B561EN06.DOC
Z axis guide rail
(see "Overview", page 6-21)
Maintenance interval: 40 operating hours.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Clean the guide rail for the gauge finger adjustment using a
lightly oiled cloth.
Z axis toothed belt
(with optional 4-axes backgauge)
(see "Overview", page 6-21)
Maintenance interval: 500 operating hours.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Check the belt tension of the toothed belt of the R axis using a
traction and pressure scale.
In case of a 7 N load, the toothed belt may only yield:
s =20 mm (TruBend 3066/3180)
s =25 mm (TruBend 3120)
s
F
s value to the extent of which
the gear belt may yield
F Load on the toothed belt
Z axis toothed belt
Cleaning guide rail
Checking the belt tension
Fig. 26490
B561EN06.DOC 6BMechanical components 6-25
X axis fixed stop
(see "Overview", page 6-21)
Maintenance interval: 500 operating hours.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Tighten the fixing screws for the fixed stops using a torque
wrench set to 8 Nm.
Note
The fixed stops must be mounted in such a way that they can be
moved from the middle of path movement outwards. When moving
the X axis unit, it must be possible to move a fixed stop.
Tightening screws
6-26 7BElectrical components B561EN06.DOC
7. Electrical components
7.1 Overview
1
5 4 4 2, 3 5 4
1 DA control system
2 Electrical leads
3 Switch cabinet with fail-safe control
system
4 Safety switches of the protective
covers
5 Optoelectronic safety device
Fig. 52858
B561EN06.DOC 7BElectrical components 6-27
1
1 Control elements at the switch
cabinet
Fig. 52977
6-28 7BElectrical components B561EN06.DOC
7.2 Maintenance instructions
Safety switch of the protective covers
(see "Overview", page 6-26)
Maintenance interval: 8 operating hours.
Danger
Be careful when switching on the machine again!
Risk of fatal injury.
Before switching on the machine again, make sure that no
one is within the danger zone of the machine.
1. Open the rear protective cover (roller gate) of the machine.
The hydraulic system of the machine shuts down
(EMERGENCY STOP function).
2. Open the side protective cover of the machine.
The hydraulic system of the machine does not shut down.
A closing movement of the beam is possible at a maximum of
10 mm/s.
If both protective covers at the side are opened, then the
hydraulic system of the machine shuts down (EMERGENCY
STOP function).
Checking the function
B561EN06.DOC 7BElectrical components 6-29
Failsafe control system PCSS-F
(see "Overview", page 6-26)
Maintenance interval: Every 3 years, regardless of the number of
operating hours.
Warning
Risk of injury due to contact of the battery with eyes and
skin!
Do not charge the battery.
Do not use force to open battery.
Do not throw batteries into fire.
Dispose of the battery properly.
Additional equipment, tools, material
Philips screwdriver
Battery
CR 2430, Lithium 3 V
TRUMPF mat. no.: 1365695
1
1
1
1
1 Screws
Replacing the battery
Fig. 52981
6-30 7BElectrical components B561EN06.DOC
Note
If the battery is not replaced within 30 seconds, the data of the
control system software and that of the kernel is lost: contact
TRUMPF Service.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Remove all plugs at the PCSS.
3. Undo screws (1) on the cover of the PCSS.
4. Remove the battery and insert a new one within 30 s.
5. Install the cover and tighten the screws (1).
6. Re-install all the plugs.
Electrical cables
(see "Overview", page 6-26)
Maintenance interval: 1000 operating hours.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Check the electrical cables for defects. Possible defects:
Damage to or brittleness of the insulation.
Deformations that do not correspond to the natural shape
of the cable (crushed sections, kinks,...).
Incorrect installation of the cable.
Checking lines
B561EN06.DOC 7BElectrical components 6-31
Switch cabinet
(see "Overview", page 6-26)
Maintenance interval: 1000 operating hours.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Keep switch cabinet free of dust.
3. Check that all clamps are firmly in place.
4. Check protective contacts, replace any that are burnt out.
Optoelectronic safety device
(see "Overview", page 6-26)
Maintenance interval: as needed.
The front pieces of the transmitter and receiver must be cleaned
regularly depending on the surrounding conditions. If this is not
done the light that is sent and received can become so faint due to
contamination that it leads to the machine coming to a standstill
when this was not intended.
Additional equipment, tools, material
Soft, clean cloth.
Window-cleaning agent.
Note
For cleaning do not use any abrasive or aggressive agents.
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Clean the disks of the transmitter and receiver with window
cleaning agent.
3. Do not polish the glass; just let it dry.
Clean and check switch
cabinet
Cleaning the transmitter and
the receiver
6-32 7BElectrical components B561EN06.DOC
B561EN07.DOC 0BNetwork card (optional) 7-1
Chapter 7
Network card (optional)
7-2 0BNetwork card (optional) B561EN07.DOC
Delem
Networking
on the
DA-W control
- 1 -
Delem
Table of contents
1. Remote desktop between a pc and the DA-W control .................................................. 3
2. How to implement networking with the DA-W control................................................ 5
2.1. Network connection ................................................................................................... 5
2.2. Direct link between a control and a pc....................................................................... 8
2.3. Modem connection between control and PC.............................................................. 9
2.4. How to arrange an incoming dial-up connection on Windows XP.......................... 10
3. Modem connection on DA-W control........................................................................... 14
4. Wireless networking on the control .............................................................................. 20
5. The Linksys Wireless Acces Point Router ................................................................... 21
6. The Linksys Wireless Ethernet Bridge......................................................................... 23
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Delem
1. Remote desktop between a pc and the DA-W control
It is possible to establish a remote connection between the DA-W control and a remote pc,
meaning that the remote pc takes control of the DA-W control. In this situation the control
screen is visible on the remote pc. From the pc, the user can operate the Delem application or
switch to Windows and adjust settings there. If the Delem application is active, it is not
possible to switch between operation modes (manual mode, programing mode, etc.) and it is
also not possible to start or stop operation.
To enable remote operation, there must be valid TCP/IP connection between the control and
the remote pc. See the next section about the several ways to establish a valid connection.
The remote pc must be equipped with a software tool known as Remote Display Control.
This software can be obtained from the Website of Microsoft.
When the software is installed and a connection is active, proceed as follows:
activate the application Remote Display Control from theWindows Start menu. An
empty window will open, meaning that the software is waiting for a remote device to
report itself to the software;
on the DA-W control, use the Windows Explorer to browse to the subdirectory
\Windows;
in this directory, double-click the icon CERdisp.exe;
When activated, a message appears about the version of the software. Click OK to continue.
the following window appears:
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Delem
In this Window, click on the button Connect. The following Window appears:
In the field hostname you should enter the name or the IP number of the remote pc to
which you wish to connect.
When this operation is succesfull, you will see the display of the control appear in a window
on the remote desktop pc. It is now possible to perform actions on the control from the remote
pc.
In case the connection between the pc and the control is done through a simple crossed UTP
cable (Ultra Twisted Pair), you must enter the IP number of the remote pc. In other cases, it is
also possible to enter the name of the pc.
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Delem
2. How to implement networking with the DA-W control
This section will describe different network possibilities for the DA-W control.
We will discuss three possible settings:
Network connection
direct link between a control and a PC through an ethernet cross-cable.
modem connection between control and PC.
2.1. Network connection
In this case, the control is connected to a standard local network. From the user point of view,
this setting is the easiest alternative. When the control is started it will receive a network
addres (IP number) from the network server.
If the network is connected to the internet, internet browsing can be done through the network
connection. To obtain contact with other pcs it is necessary to know which IP number they
got from the network server or which name they have.
DA-W
control
Network
UTP UTP
PC
In this situation, the network settings of the control must be as such, that the control will
obtain an IP number from the network server.
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Delem
To check and adjust the network settings, open the Windows Control Panel. It should look as
follows:
In this screen, double-click the icon Network and dial-up connections. the following screen
appears:
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Delem
This screen can also be entered directly from the start menu by scrolling to settings and
choosing Network and dial-up connections.
The second icon, PCI-RTLxxxx, represents the built-in ethernet connector. To modify the
settings, select the icon, open the file menu and select properties. A new window appears
in which the settings of the ethernet port can be edited.
Select the setting obtain an IP address via DHCP. This way, the control will receive an
address fom the server. Such a setting should be active on every pc, that is connected to the
same network.
If this setting is active and you wish to view your own network settings, double-click on the
network symbol in the Windows taskbar:
A window with network information will appear:
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Delem
2.2. Direct link between a control and a pc
DA-W
control
PC
UTP (cross)
In this situation, there is no network available. The pc and the control are connected directly
through a UTP cable. The cable should be a crossed UTP cable.
As soon as the two machines are connected, click on the network symbol as shown before. In
the network information window, click on the button Renew. The IP number of the control
will change to 0.0.0.0. Now wait until the IP number changes again. It should change to a
number starting with 169.254.... Check the same on the pc. The control and the pc can still be
used for remote display operation. In this situation, however, you must enter the IP number of
the pc in the connect dialog to get a connection.
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Delem
2.3. Modem connection between control and PC
In this situation, the control uses a modem to make a dial-up connection to the remote pc.
Both systems are equipped with a modem.
DA-W
control
Telephone network
PC
Modem Modem
The pc must be equipped with dial-up server software to accept incoming calls from the
control. From the control, a dial-up connection is initiated.
The procedure to initiate a dial-up connection on the control is explained in detail in chapter
3.
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Delem
2.4. How to arrange an incoming dial-up connection on Windows
XP
- 10 -
Delem
- 11 -
Delem
Important:
Check these user accounts. When making the dial-up connection from the control, you must
have a valid username and password from one of these accounts to be able to make a
connection.
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Delem
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Delem
3. Modem connection on DA-W control
This chapter serves to describe how a modem connection is established on a Delem DA-60W
control. A DA-60W control is equipped with a Windows operating system which gives the
user the possibility to act as an internet client. In this description the assumption is made that
the control is not connected to an ethernet LAN but is equipped with a modem that is
connected to the serial port of he control. Through this modem, it is possible to make a dial-up
connection to an Internet Service Provider (ISP) and thus obtain access to the internet.
Of course, the control must also be equipped with an internet browser (i.e. Internet Explorer).
After making a valid internet connection, the browser should have no trouble browsing the
internet.
The settings for a dial-up connection are initiated from the appropriate control panel, which is
directly accessible from the Windows Start menu:
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Delem
In the control panel, click 'make new connection'.
In the window that appears, select 'dial-up connection'. In the top of the window, type the
name you wish to give your connection.
Click 'next' to proceed.
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Delem
In this window, select the correct modem from the pop-down list. For a standard modem, you
should select 'Hayes compatible on COM1:'. The name COM1: refers to the serial interface at
the side of the main board, with the standard 9-pole sub-D connector.
The button 'TCP/IP Settings' and the button 'Security settings' give access to more advanced
settings. If you are an experienced internet user, you could select these functions and enter
more specialised settings. If not, it is best to leave these functions alone at his time.
The button 'Configure' is used to adjust the modem settings.
Normally, most of these settings are correct, but you should check whether the baud rate is set
to the correct speed. Check your modem specifications for the correct settings. If correct, click
'OK' to return to the modem connection dialog. Click 'next' to continue.
The next window shows the phone number codes of your ISP: country code, area code and
phone number.
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Delem
Make sure to enter these fields correct, so that the control will dial the correct number. When
the numbers are entered, click 'Finish'. The connection is created. When you look at the
screen, you will see an extra icon has been added with your connection name below it.
Your connection is not complete yet. Double-click the connection icon to open your
connection. In the dialog that appears, enter your user name and password with which you can
identify yourself to the ISP.
If you must use this connection often, it can be useful to select 'save password'. This way, the
connection is opened quickly when it is called for.
Click the button 'dial properties'.
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Delem
A new window opens, in which area codes for several locations can be set. Enter the codes for
the appropriate area and country. When the control will start to dial the ISP, it will compare
the country and area code of the ISP with the codes that you have programmed here. When
those codes are the same (meaning the control is in the same area as the ISP), the control will
omit those codes from the dial string and dial the ISP directly. Click the button 'New' to
program a new location from where you will call.
Click the button 'Dialling patterns' to program the manner in which the control will dial the
ISP.
In this window, three methods are shown how to call the ISP:
make a local call (the ISP is in the same area as the control)
make a long distance call (the ISP is in a different area as the control, but still in the
same country)
make an international call (the ISP is in another country)
When the call is made, the control will compare the dial codes of the ISP with the codes of the
control. Based on this comparison, the control will choose one of the dial methods: local, long
distance or international.
The characters E, F and G are used to represent the numbers for country, area and phone
number. A comma stands for a short pause before dialling. Any other character that is entered,
will be interpreted literally.
When a local call is made, the control will dial the number as is indicated in the first field. For
a long distance call, the directions in the second field are followed and for an international call
the directions in the third field are followed.
For example, the direction for a local call could be:
,G
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Delem
As is indicated at the bottom of the screen, G represents the telephone number of the ISP. So
when the control has determined the ISP and the control are in the same area, the control will
simply dial the telephone number.
The directions for a long distance call could be:
,0FG
The string begins with a zero, because in the case of a long distance call the number must start
with a zero. The F stands for the area code and the G stands for the ISP number.
Example:
A Delem control has been installed in Eindhoven, the user wishes to contact its ISP in
Amsterdam. The local area code of Eindhoven (where the control is located) is 40, the country
code of the control 31 (the Netherlands).
The area code of the ISP is 20 (Amsterdam), the country code of the ISP is 31 (the
Netherlands), the number of the provider is 1234567.
When the connection icon is opened, the control will check the data of the ISP. He will
determine that the control and the ISP are in the same country but not in the same area, so the
directions for a long distance call must be followed:
,0FG
This string is interpreted as follows:
, = (short pause)
0 = 0
F = 20
G = 1234567
So upon 'connect', the modem will dial: 0 20 1234567.
When the settings have been entered correctly, click on 'OK' in the upper right corner of the
screen to return to the initial dial-up window. In this window, the resulting phone number is
displayed that will actually be called by the modem. Click 'connect' to start the call and open a
connection to your ISP.
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Delem
4. Wireless networking on the control
It is possible to connect the control to a wireles network. For instance, through a wireless
ethernet bridge that translates network data between wired and wireless networks. The device
has a standard ethernet port to which a computer or a DA-W control can be connected.
DA-W
control
Network Router
UTP
UTP
Wireless Wireless
Wireless
ethernet
bridge
This is another example of networking possibilities. Also in this case, the network protocol is
TCP/IP. Although the connection is made through a wirelesse device, the network
organisation is the same as described in section 2.1 concerning a normal network.
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Delem
5. The Linksys Wireless Acces Point Router
This device is both a network hub and a small network server. It can supply network adresses
(IP-numbers) to all connected clients.
DA-W
control
Network Router
UTP UTP Wireless
A client (a pc or a DA-W control) can be connected through a UTP cable or through a
wireless connection. In both cases, a client receives an IP-number from the Router.
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Delem
The settings of the Router can be adjusted, it necessary. For this purpose, the Router has a
small integrated webserver. This webserver can be from any of the connected clients through
their webbrowser. When a user attempts to connect, he will have to enter a username and
password. If these are entered correctly, a web page opens in which several router settings can
be adjusted.
Default, both the username and password of the Router are set to admin. For safety reaons,
you may wish to change this.
For wireless networking, the field SSID may have to be edited. A network between wireless
devices will only function if these devices have the same SSID.
- 22 -
Delem
- 23 -
6. The Linksys Wireless Ethernet Bridge
This device translates network signals between a wired and a wireless network. As already
shown in the previous section, it enables a computer to connect to a wireless network.
Network Router
UTP
o WLAN
Wireless
Wireless
ethernet
bridge
LAN
X II
o LAN
Points of interest when connecting:
Make sure the bridge device has power
Make sure the client (a pc or a DA-W control) is connected to the LAN port of the
bridge. If the LED with the indication LAN is lit, the client is connected correctly. If
the LED is not lit, check your cabling. If the cabling is sound, change the setting of the
switch with the cross and the stripes.
Make sure the device reognises the wireless network. If the LED with the indication
WLAN is lit, the wireless network is sound. If no wireless network is recognised, it is
possible that the several devices do not have the same SSID.
B561EN08.DOC Index 1
Index
2
2D.. ............................................................ 4-23
A
Ambient conditions ...................................... 2-6
Ambient temperature................................... 2-6
ASV................................................... 1-21, 4-34
Switching between MSC and ASV...... 4-34
Axis
Moving manually................................. 4-39
B
Backgauge.......................................... 3-6, 3-16
2-axis................................................... 3-17
4-axis................................................... 3-17
5-axis................................................... 3-17
Beam........................................................... 3-9
Bend, individual
Programming....................................... 4-26
BendGuard....................................... 3-26, 4-16
Checking the laser beam.................... 5-17
Installing.............................................. 5-14
Magnetic plate..................................... 3-29
Removal.............................................. 5-13
Setting the height................................ 5-16
BendGuard mode...................................... 4-16
Bending...................................................... 4-37
Step by step........................................ 4-38
C
CE marking.................................................. 1-4
Connected loads.......................................... 2-8
Control panel ............................................. 3-12
Control system...........................3-13, 3-14, 4-8
Crowning.................................................... 3-10
Hydraulic............................................. 3-11
Mechanical.......................................... 3-11
D
Danger ....................................................... 1-25
Danger zone ................................................ 1-6
Dies.....................................................3-18, 5-9
Loading..................................................5-9
E
EC Machinery Directive......................1-4, 1-25
EMERGENCY STOP ................................. 4-12
Entering alphanumeric characters............. 4-15
Entering letters........................................... 4-15
F
Floor......................................................2-4, 2-5
Base plate.............................................. 2-5
Floor requirements ................................ 2-4
Foot operation.............................................. 4-7
Foot switch..........................................3-15, 4-3
Activating............................................. 4-11
Additional lights ................................... 3-24
Four-hand operation...........................4-7, 4-10
Frequency.................................................... 2-8
Fuse protection............................................ 2-8
G
Gauge finger.......................................3-16, 5-3
Adjusting gauge finger........................... 5-3
Grease nipple................. 6-12, 6-13, 6-14, 6-15
2 Index B561EN08.DOC
H
Humidity....................................................... 2-6
Hydraulic oil ............................................... 2-12
Hydraulic system......................................... 3-9
Switch off............................................... 4-7
Switching on.......................................... 4-7
I
Inclined position of the beam....................... 3-9
Installation site............................................. 2-4
K
Key switch
Description............................................ 4-7
L
Light curtain...................................... 3-31, 4-16
Aligning transmitter and receiver ........ 5-18
Checking the function......................... 5-19
Light curtain mode..................................... 4-18
Lower tool
Drawing............................................... 4-27
Lubrication................................................... 6-5
M
Machine....................................................... 3-3
Axes ...................................................... 3-7
Operating without BendGuard............ 4-19
Operating without light curtain............ 4-19
Switching off........................................ 4-14
Switching on........................................ 4-12
Total weight........................................... 2-5
Machine axes .............................................. 3-7
Machine dimensions.................................... 3-4
Machine frame............................................. 3-9
Magnetic plate........................................... 3-29
Maintenance ................................................ 6-4
Ballscrew............................................. 6-14
Changing the oil filter............................. 6-8
Check oil level ....................................... 6-7
Failsafe control system........................ 6-29
Gauge finger displacement................. 6-24
Hydraulic hose lines ............................ 6-17
Hydraulic system................................... 6-7
Protective cover................................... 6-28
R axis...................................................6-13
Switch cabinet..................................... 6-31
Tool holder........................................... 6-22
X axis................................................... 6-12
X axis, fixed step................................. 6-25
Z axis................................................... 6-15
Z axis, toothed belt.............................. 6-24
Manual operator console....................3-25, 4-4
Activating............................................. 4-11
Modifying language.................................... 4-33
MSC..................................................1-21, 4-34
Switching between MSC and ASV...... 4-34
O
Occupational safety................................... 1-29
Oil 2-12, 6-7
Changing the oil .................................. 6-10
Oil quantity................................................. 2-12
Oil temperature............................................ 2-6
Operating elements........................4-3, 4-5, 4-8
Operating mode keys................................... 4-9
Operating modes ....................................... 4-10
Operator....................................................... 1-6
Options....................................................... 3-24
4-axes backgauge............................... 3-17
5-axes backgauge............................... 3-17
Additional foot switch........................... 3-24
BendGuard.......................................... 3-26
Foot switch............................................ 4-3
Four-hand operation.....................4-7, 4-10
Light curtain......................................... 3-31
Manual operator console..............3-25, 4-4
Manual tool clamping.......................... 3-20
Network connection............................. 3-26
Pneumatic tool clamping.....3-21, 5-8, 5-10
Quick Clamp.......................................... 5-6
Robot operation..................................... 4-7
Support bracket................................... 3-21
Two-foot mode .................................... 4-10
Two-foot operation................................ 4-7
Two-hand operation.....................4-7, 4-10
B561EN08.DOC Index 3
Optoelectronic safety device...3-26, 3-31, 5-13
BendGuard................................. 4-16, 5-13
Light curtain................................ 4-18, 5-18
Optoelectronic safety devices.................... 4-16
P
Personnel...................................1-6, 1-14, 1-28
Pneumatic tool clamping........................... 3-21
Power supply............................................... 2-7
Program
Back up............................................... 4-29
Creating............................................... 4-21
Creating graphically............................ 4-23
Creating manually............................... 4-21
Interlinking........................................... 4-22
Loading............................................... 4-20
Management....................................... 4-29
Modifying............................................. 4-26
Saving................................................. 4-29
Programming mode................................... 4-10
Protective gear ................................. 1-16, 1-31
R
R-axis........................................................... 3-7
Robot operation........................................... 4-7
S
Safety concept........................................... 3-26
Safety information...................................... 1-29
Safety mode
Selecting............................................. 4-19
Safety-Click
.............................................. 3-23
Setting the program data........................... 4-33
Setup mode................................................. 4-7
Speeds......................................................... 3-4
Rapid speed.......................................... 3-4
Spindle return speed............................. 3-4
Working speed...................................... 3-4
Step change
Programming....................................... 4-36
Switch cabinet ............................................. 4-5
Switching off .............................................. 4-14
Switching on.............................................. 4-13
T
Technical specifications............................... 3-4
Temperature range...................................... 2-6
Tool
Creating............................................... 4-27
Management ....................................... 4-31
Saving.................................................. 4-31
Tool clamping............................................. 3-18
Manual......................... 3-19, 3-20, 5-5, 5-9
Pneumatic............................3-21, 5-8, 5-10
Quick Clamp.......................................... 5-6
Tools .......................................................... 3-22
Back up................................................ 4-31
Setting up.............................................. 5-4
Special tools........................................ 3-23
Total weight of the machine......................... 2-5
Transport.................................................... 2-13
Two-foot mode........................................... 4-10
Two-foot operation....................................... 4-7
Two-hand operation...................3-26, 4-7, 4-10
U
Upper drive .................................................. 3-9
Upper tool
Drawing............................................... 4-28
Upper tool clamping
Dismantling segment........................... 5-11
Installing segment ............................... 5-12
Upper tools..........................................3-18, 5-4
Loading..................................................5-4
USB data carrier
Saving a program................................ 4-29
Saving tools......................................... 4-31
User.............................................................. 1-6
User interface
Structure.............................................. 4-10
Using Online help....................................... 4-15
V
V axis ......................................................... 3-10
X
X axis ........................................................... 3-7
4 Index B561EN08.DOC
Y
Y axis........................................................... 3-7
Z
Z axis............................................................ 3-7