Trumpf TC500R Operation Manual

Operator's manual
TC 500R
Operator•s Manual
TC 500R
Edition: 01/2001
Ordering information Please state title of document, desired language and date of
edition.
TRUMPF Maschinen GmbH + Co KG

D-71254 Ditzingen
Johann-Maus-StraBe 2
Phone (0 71 56) 303-0
Fax (0 71 56) 303-540
Internet: http//www.trumpf.com
e-mail: docu.501@de.trumpf.com
This document was compiled by the Technical Documentation Dept. of

TRUMPF Maschinen GmbH + Co. KG.
All rights, in particular the right to reproduce, distribute or translate this
documentation, are reserved to TRUMPF Maschinen GmbH + Co. KG, also in
the case of applications for patents and industrial rights. No part of this
documentation may be reproduced, processed, duplicated or distributed by
means of electronic systems in any form whatsoever without the prior written
consent of TRUMPF Maschinen GmbH + Co. KG. Subject to errors and
technical changes.
© TRUMPF Maschinen GmbH + Co KG

TRUMPF Maschinen GmbH + Co. KG cannot be held responsible for possible
mistakes in this documentation. Any warranty for direct and indirect damages,
arising in connection with the delivery or the use of this documentation, is
excluded, as far as this in conformity with the law.
TRUMPF
Before you continue ...
Operator's Manual This Operator's Manual serves to document the TRUMATIC 500
TRUMATIC 500 ROTATION sheetmetal working machine.
ROTATION
This manual is addressed not only to the user (owner) and operator of the
machine, but also to its maintenance personnel. This group of persons
must have access to the manual.
Contents of the □ Chapter 1: Safety

Operator's Manual □ Chapter 2: Technology
□ Chapter 3: Installation, Operation and Transport
□ Chapter 4: Description
□ Chapter 5: Operation
□ Chapter 6: Maintenance
□ Chapter 7: Interface description
□ Chapter 8: System messages
□ Appendix
Reference Guides Besides the Operator's Manual, the machine documentation also includes
the:
□ Programming manual
o TRUMAGRAPH Manual
□ Spare parts list
□ Schematics
□ Folder: Vendor-supplied documentation
Handbooks on the programming systems and material for use in training

courses are also available.
& The entire machine documentation contains vital safety information

regarding prevention of injuries and potential hazards to life and health.
The symbol to the left calls your attention to information of this type. Be
sure to read the Safety chapter!
B119E0 Before you continue... 0-5

0-6 B119E0
Contents
Chapter 1 Safety
1. For your safety . . 1-2
2. Terminology. . . . 1-3
3. Operating safety .
.1-3
3.1 Authorized application of the machine . . . .
. 1-3
3.2 Measures to be taken by the owner/operator.
. 1-4
3.2.1 Observance of safety notes and warning plates .
. 1-4
3.2.2 Instructing the personnel. . . . . . . . . . . . .
. 1-5
3.2.3 Necessary diligence and care in operating
the
. 1-5
machine................... .
3.2.4 Procedure in the event of malfunctions.....................................1-7
3.2.5 Use of authorized spare parts and utilities................................ 1-7
3.3 Safety measures implemented by the manufacturer.................1-8
4. Overview of dangers....................................................................1-9
Chapter 2 Technology
1. Introduction.................................................................................. 2-2
2. Mechanical cutting processes.....................................................2-2

2. Punching. . 2-2
1
2. Nibbling .. . 2-4
2
3. Tensile strength Rm of metallic materials..................................2-6
4. Tables of maximum capacities....................................................2-9
B119E0 Contents 0-7

TRUMPF
4.1 Formulas...................................................................................2-9
4.2 Influencing factors . 2-10
4.3 Dies... 2-11
4.4 Punches 2-12
4.5 Overview of tables . 2-12
5. Feed . . . . . . . . . . . . . . . . 2-15
5.1 Feed per stroke when nibbling. 2-15
5.1.1 Feed per stroke for round tools . 2-15
5.1.2 Feed per stroke for square or rectangular tools 2-17
5.1.3 Feed per stroke with slitting tools, oblong tools
or tools with corner radius . . . . . . . . . .. 2-18
5.1.4 Punch dimensions recommended for nibbling . 2-18
6 Slotting tool (Option). . . . . . . . . 2-19

.
7 Coordinate system, axes direction. 2-21
.
8 Tool magazine . . . . . . . . . . . . . . . . 2-23
.
8. Magazine stations . . . . . . . . . . . . . 2-23
2
8 Dead area of standard workpiece clamps. 2-27
.
2
9 Working and overshoot ranges. 2-29
.
9 Working range Y1300 . 2-29
.
1
9 Working range Y1600 . 2-31
.
2
1 Stop pin . . . . . • · · · · 2-32
O
.
1.8 Contents B119E0
Chapter 3 Installation, Operation and
Transport
1. Installation Site.............................................................................3-3
1.1 Space requirements......................3-3
1.2 Floor requirements......................3-3
1.3 Weight distribution.....................3-3
1.4 Ambient conditions........................................................................3-6
2. Power supply................................................................................3-7
2.1 Electric Network........................3-7
Notes on the Isolating Transformer... . . .3-8
2.2 Current loads, current intensities...................................................3-9
2.3 Teleservice..............................3-9
2.4 Network Connection......................3-9
3. Pneumatic Connection..............................................................3-11
4. Oils and Lubricants....................................................................3-13

4.1 Oil for the hydraulic system........................................................3-13
4.2 Lubricants for spray tool lubrication............................................3-14
4.3 Materials......................................................................................3-14
5. Maschine Transport...................................................................3-15
5.1 Work to be performed by the customer......................................3-18
5.2 TRUMPF service work................................................................3-18
6. Planning Aid...............................................................................3-19
B119E0 Contents 0-9

TRUMPF
Chapter 4 Description
1. Technical specifications. . 4-2
2. Machine sub-assemblies . 4-3

2.1 Machine Frame. . . 4-4
2.2 Coordinate Guide . 4-5
2.3 Removal of workpieces and . 4-6
scrap.
. 4-8
2.4 Punching Head. . . .
.4-10
2.5 Workpiece Clamping.
.4-11
2.6 Rotary Tool adapter .
3. Tools . . . . . . . . . . . .4-12
3.1 Criteria for tool selection .4-12
3.2 Description of the tool system. .4-13
3.3 Criteria for punch
selection
.4-17
3.4 Components of a tool set
.4-17
3.4.1 Alignment ring
.4-17
3.4.2 Dies ....
.4-18
3.4.3 Strippers .
5. Retractable Clamps (Option) . .4-22

5.1 Technical Data. .4-22
5.2 Function .... .4-23
5.2.1 While machining . .4-24
5.2.2 During tool change . 4-25
While loading and unloading . .4-26
Manual loading and unloading . .4-26
Pushout of parts . . . . . . . . .4-27
5.2.4 Loading/Unloading with TRUMALIFT SheetMaster
1300/1600 ..................... .4-28
.
6. Machining with scratch minimization . .4-29
7. Sensor stop pin. . .4-32
8. Reference Guides .4-33
0-10 Contents B119E0

Chapter 5 Machine operation
Part 1: Operating Elements.................................................................5-2
1. Description of operating elements. . 5-2

1.1 Operating elements away from the operator's panel. . 5-3
1.2 Operating elements at the operator's panel. . 5-4
1.2.1 Control system (TRUMAGRAPH CC220 S)
operating elements. . . . . . . . . . . . . . . 5-4
1.2. Overview of main operating modes . . . . . . 5-5
2
Operating elements of the TRUMPF CNC control . . 5-6
1.2.
3
TC 500R without automation components.
. 5-6
TC 500R with automation components
. 5-7
TRUMALIFT SheetMaster diagnostics.
. 5-8
Explanation of the operating elements.
. 5-9
2. Workplaces at the machine . .5-11
Part 2: Examples of operation ..

.5-12
1.
Machine start-up and shutdown. . . . . . .5-13
1.
Starting the machine up at the beginning
1
of the workday . . . . . . . . . . . . . . . .5-13
1.2 Machine shutdown during malfunctions/in
emergencies . . . . . . . . . . . . . . . . .5-14
1.3 Machine shutdown at the end of the workday .5-15
2. Program execution . . . . . . . . . . . . .5-17

2.1 Running a program in automatic mode . .5-17
2.1.1 The tools have been loaded . .5-17
2.1.2. No tools have been loaded . .5-18
2.2 Running a Program with Softpunch. .5-20
2.3 Executing a single stroke . . . .5-21
2.4 Program stop while machining. .5-22
2.5 To interrupt a program. . . . . .5-23
B119E0 Contents 0-11

3. Resuming a NC program after an interruption . .5-24
3.1 Resuming via "Search Block"................................................... 5-24
3.2 Resuming via "Go Block"......................................................... 5-27
3.3 Resuming a program via "Simulation"...................................... 5-29
3.3.1 When using a punching tool..................................................... 5-29
3.3.2 When using a tapping tool .5-31
4. Service and diagnostic functions..............................................5-35

4.1 Securing the axes against unauthorized
intervention............................................................................... 5-35
4.2 Machine status display (MSD)................................................. 5-35
4.3 Displaying inputs and outputs.................................................. 5-36
4.4 Checking the software version................................................. 5-37
4.5 Activating the screen saver...................................................... 5-37
4.6 Cursor bar for faster operation .5-38
4.7 Setting the date and time .5-39
4.8 Sorting files.............................................................................. 5-39
5. Solutions to problems: .5-40
6. Program Input and Output..........................................................5-43

6.1 Device connection and settings............................................... 5-43
6.2 Uploading NC programs........................................................... 5-44
6.3 Uploading graphic programs.................................................... 5-46
6.4 Uploading NC programs via PC/TC TRANSFER .5-48
6.5 Downloading NC programs..................................................... 5-52
6.6 Downloading graphic programs............................................... 5-55
6.7 Downloading NC programs via PC/TC TRANSFER.................5-58
7. Management of programs and tables........................................5-61

7.1 Deleting NC programs............................................................. 5-61
7.2 Deleting graphic programs....................................................... 5-62
7.3 Displaying an NC text.............................................................. 5-64
7.4 Editing an NC text (examples)................................................. 5-65
0-12 Contents B119E0

8. Tools and tool tables..................................................................5-76
8.1 Creating tool tables and loading tools into
8.2 the linear magazine ........... .5-76

.
.5-79
Creating a tool table when using Multitools.
8.3 Tooling the linear magazine/Exchanging tools
(examples)..............................................................................5-81
9. Job tables (SheetMaster linkage)..............................................5-87

9.1 Creating/Editing a job table . .5-88
9.2 Sorting job data . . . . .. 5-91
9.3 Searching for job data . .. 5-92
9.4 Deleting job data. .. 5-93
9.5 Processing jobs . . . . ... 5-94
Chapter 6 Maintenance
1. General Guidelines. . . . 6-2
2. Maintenance Overview. . 6-3
3. Machine lubrication . . . 6-5

3. Lubrication Diagram . . 6-5
1
3.2 Explanation of symbols in lubrication diagram . . 6-5
3.3 Lubricant table...........................................................................6-6
3.4 Lubrication Plan: Explanations . 6-8
4. Maintenance: Hydraulic machine components........................6-17

4.1 Depressurizing the accumulators............................................6-17
4.2 Maintenance plan: Hydraulic machine components................6-18
4.3 Maintenance plan: Explanations.............................................6-19
4.4 Recharging the gas chamber of the hydraulic
4.5 accumulator with nitrogen . . . . . . . . . . . .6-21

Using a charging and testing fixture for hydraulic
accumulators. . . . . . . . . . . . . . . . . . . . .6-22
8119E0 Contents 0-13

5. Maintenance: Pneumatic machine components.......................6-26
5.1 Maintenance plan: Pneumatic machine
components.............................................................................. 6-26
5.2 Maintenance plan: Explanations............................................... 6-27
6. Maintenance: Mechanical machine components.....................6-30

6.1 Maintenance plan: Mechanical machine
components.............................................................................. 6-30
7. Maintenance: Electrical machine components.........................6-38

7.1 Maintenance plan: Electrical machine components .6-38
8. What to do after a collision......................................................... 6-41
9. Regrinding tools .6-42

9.1 Compensating the tool regrind length .6-43
9.2 Choosing a suitable die . . . . . . . . .6-44
1.14 Contents B119E0

TRUMPF
Chapter 7 Interface Description

1. Interface Description 20mA/V24..................................................7-2
1.1 General information . . 7-2

1.1.1 Important note ... .. 7-3
1.1.2 Basic equipment .. .. 7-4
1.1.3 Machine parameters . . 7-4
1.1.4 Device parameters. . 7-4
1.1.5 Control signals . . . 7-5
1.1.6 Interface settings. . 7-6
1.2 Device control . . . 7-6

1.2.1 Module function . 7-6
1.2.2 Control characters . . 7-6
1.2.3 Activation . . . . . . 7-7
1.3 Interface selection . . 7-7

1.3.1 CP/MEM 4 board . 7-8
1.4 Technical data, signal leads 20 mA . 7-9

1.4.1 Technical data (20 mA) . 7-9
1.4.2 Signal leads (20 mA). . . . . . .. .. 7-9
1.5 Technical data, signal leads V24 . . .7-10

1.5.1 Technical data (V24). .7-10
1.5.2 Signal leads (V24) . . . . . . . . . .. 7-10

1.6 Pin assignment - interface 1 and 2. . .. 7-11
1.6.1 V24 with software handshake . ... 7-11
1.6.2 V24 with hardware handshake . . ... 7-11
1.7 Pin assignment serial interface 1 20 mA ... 7-12

.
... 7-12
1.7.1 20 mA interface with software handshake
... 7-14
1.7.2 20 mA with hardware handshake . . .
.. 7-16
1.8 Output from the control to data media.
1.9 Input to the control from data media...................................7-16
Chapter 8 System messages

1. General guidelines . 8-2
.
. 8-3
2. System messages .
Appendix
1. Measuring report. . . .. 9-4
2. Measuring results . .. 9-5
3. Drawing: Workpiece................................................................... 9-6
4. Drawing: Location of measuring points................................9-7

1. Alignment accessories .9-10
2. Installation example . .9-11
3. Alignment procedure .9-11

TRUMPF

Chapter 1
Safety
B119E1 Safety 1-1

1. For your safety
With the TRUMATIC 500 ROTATION you have at your disposal a
punching and nibbling machine which, in terms of safety, is state-of-the
art and safe in operation.
With this declaration of EC conformity and the CE marking on the
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machine, we confirm that the TRUMATIC 500 ROTATION complies with

the relevant regulations on occupational health and safety as stipulated in
the EC Machinery Directive 89/392/EEC.
Nameplate and CE symbol Fig. 8786
The nameplate, together with the CE marking, is affixed to the hydraulic

unit of the machine.
Despite all the measures that have been implemented, however, the
machine may still represent a source of danger if incorrectly operated by
untrained personnel or if used for unauthorized application.
As the manufacturer of the machine, we would like to acquaint you, the
user, with the safety concept of the machine and alert you to possible
dangers and measures in this comprehensive chapter on safety.
1-2 Safety B119E1
In addition to the guidelines provided in this manual, the general
regulations governing safety and accident prevention must also
be observed!
2. Terminology
Danger area This is the area within and peripheral to the machine where the safety or
health of persons is endangered. The danger zone comprises an area
which can be covered by the transverse rail while carrying a workpiece
(centered on the rail) that corresponds in size to the nominal working
range of the machine, plus an additional margin of 500 mm on all sides.
This area must be protected with safety equipment (e.g. fences, light
barriers).
Owner This is the party in whose plant the machine is installed and operated.
Operator/Personnel These are the persons charged with the transport, installation, start-up,
operation, maintenance including cleaning, and elimination of faults on
the machine.
3. Operating safety
The machine is of state-of-the-art design and is built for safe operation.
This machine, however, may represent a source of danger if it is
operated by untrained personnel or if incorrectly operated. This will
&
□ endanger the safety of the operator
□ depreciate the machine and other assets of the owner's
□ impair the efficiency of the machine
3.1 Authorized application of the machine

The machine is a CNC sheet metalworking machine for punching,
nibbling and forming in flat workpieces made of steel, copper, aluminium
and corresponding alloys. Regulations DIN 1016 and Euronorm 29 - 81
serve as guidelines governing the required flatness of workpieces.
Liability voided in the Any application beyond and above this shall be construed as unauthori
event of unauthorized zed application. The manufacturer shall not be held liable for any
application! damages resulting therefrom; the entire risk rests solely with the user.
B119E1 Safety 1-3

Authorized application also requires full compliance with the conditions
specified by the manufacturer in regard to installation, operation,
transport and maintenance of the machine.
Machine installation and operation must comply with the local safety
codes currently in force in the owner's country. The owner shall be
responsible for their compliance.
All work procedures which impair the functioning safety of the equipment
must be avoided.
Modifications to the
Unauthorized changes or modifications to the machine by the owner or
machine
the operator are strictly prohibited; the manufacturer shall not be held
liable for any injury to persons or material damage resulting therefrom.
3.2 Measures to be taken by

the owner/operator
3.2.1 Observance of safety notes and

warning plates
Warning plates on the
Warning plates have been affixed to the machine, warning against:
machine
□ Touching any live components (1)
□ Electrostatic charging of control components (2)
•
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Warning plates on the machine Fig. 3457

Authorized application also requires full compliance with the conditions
Labels bearing the warning ATTENTION! UNDER VOLTAGE EVEN

WHEN MAIN SWITCH IS OFF must be affixed to machined components
which already tap their supply voltage before the main switch.
Caution: These parts carry voltage even when the main switch is OFF!
1-4 Safety B119E1

This applies not only to the standard tank heater but also to all other
Caution!
equipment installed, such as the switch cabinet lighting.
Do not switch tank heater on
The warning plate on the left must also be affixed to the hydraulic unit.
unless oil container Is full!
Disconnect from power supply
before proceeding with
maintenance (oil change,
replacing the tank heater)!
& These warning plates and other danger signs must be observed without
fail.
3.2.2 Instructing the personnel

Instructing the Only authorized, trained and suitably instructed personnel may be
personnel entrusted with the operation, maintenance and service of the machine.
This personnel must receive specialized instruction regarding possible
hazards. This applies in particular to electrical, pneumatic and hydraulic
installation work which may be undertaken only by trained personnel.
Reading the machine

The complete technical documentation on the machine should be made
documentation
available for study to all persons charged by the owner with the
operation, maintenance and service of the machine. It is recommended
that the owner obtain written confirmation from his staff that they have
studied and understood the documentation.
Areas of competence The areas of competence in the matter of maintenance, operation and
servicing must be clearly defined in order to avoid any ambiguity
concerning responsibility for the safety aspects of machine operation.
3.2.3 Necessary diligence and care in

operating the machine
Never operate the machine unless you are sure the appropriate safety
equipment for safeguarding the work area is functional.
Operation only in It is the responsibility of the owner, or of the parties entrusted by him, to
perfect condition ensure that the machine is run in perfect working order at all times.
The owner undertakes to ensure that the workplace at the machine is

maintained in a clean and orderly condition by issuing appropriate
instructions to this effect.
& The owner must, whenever necessary, require his employees to wear
protective clothing and hearing protection.
B119E1 Safety 1-5

The owner must ensure proper ventilation (fresh air) in the hall where the
machine is operated.
The owner undertakes to install the machine in compliance with the

installation plan and installation conditions.
It is also the operator's duty to assure that only authorized persons are
allowed to work at the machine.
danpA
Monitoring the Before powering the machine up, the operator must always assure
himself, with the help of the mirror on the light barrier pedestal, that all
& persons are clear of the danger area.
Reporting The operator shall inform the owner immediately of any changes
malfunctions and (including changes that interfere with the functional properties) at the
damages machine that detract from operating safety. The machine should be
visually inspected in every shift to detect defects and damage.
Inspecting and The owner or the operator is not permitted to dismantle or shut down any
servicing the safety safety equipment. If set-up, maintenance or service work makes it
equipment necessary to dismantle or shut down such safety equipment, it is
imperative that these safety devices be reassembled or reactivated
immediately upon completion of such work.
The function of the light barrier should be examined once per shift
(preferably at the start of production). Light barrier function should also be
checked if the light transmitter and light receiver are relocated, and after
any maintenance and service work on the light barrier.
Observance of The shutdown procedures described in the operating instructions must be

shutdown procedures observed before beginning any work involved with the transport,
installation, commissioning, operation, maintenance and service of the
equipment.
The main switch must always be turned off and locked before
undertaking any adjustments, maintenance and service work on the
machine unless indicated otherwise. In addition to this, the pressure
accumulators must be depressurized before working on the hydraulic
system, and the compressed air turned off before working on the
pneumatic system.
Any tasks which, in departure from this rule, require that the machine
remain powered up, are specified in this manual.
1-6 Safety B119E1

3.2.4 Procedure in the event of malfunctions
FEED HOLD
The operator must immediately press the FEED HOLD key if a
malfunction occurs while the machine is running.
EMERGENCY STOP
If the malfunction cannot be rectified from the control panel, press the
EMERGENCY STOP button before any intervention at the machine itself.
Shutdown via the
The machine must be shut down by turning off the main switch if
main switch
maintenance or service work is involved, and not just the simple
elimination of temporary faults.
3.2.5 Use of authorized spare parts and utilities

Using original parts
Original parts and accessories have been designed especially for the
machine. Replacements for these original parts and accessories other
than those supplied by the machine's manufacturer are not inspected and
approved by the manufacturer. The incorporation and/or use of such
products may, therefore, have an adverse effect on the function of the
machine and diminish its safety.
Liability disclaimer The manufacturer shall not be held liable for any damage incurred
through the use of non-original parts and accessories or through
improper installation or replacement of original parts and accessories.
Guidelines for use of The relevant directions for the use of utilities (especially lubricants and
utilities cleaning agents) must be observed. If the manufacturer has stipulated a
certain DIN safety data sheet (DIN 52 900) for any of the utilities, the
information contained therein concerning:
□ Chemical properties
□ Physical and technical safety specifications
□ Transport
□ Regulations
□ Protective measures, storage and handling
□ Steps necessary in the event of accident and fire
□ Toxicological information
□ Ecological information
shall be binding. This applies, in particular, also to the correct disposal of

waste matter. The proper methods of waste disposal are indicated in the
safety data sheet which can be obtained from the manufacturer of the
utility in question.
B119E1 Safety 1-7

3.3 Safety measures implemented by
the manufacturer
Light barrier The standard machine is equipped with a dual-beam light barrier for
safeguarding the danger zone. The owner is free to use his own
equipment to protect the danger area, in which case he assumes
responsibility for compliance with the safety regulations.
Machine protection by means of light barriers is effective in all operating

modes of the control.
If light barriers are used, interruption of the light path during operation will
cause all machine motion to be halted. This is equivalent to pressing the
FEED HOLD button.
Machine shutdown caused by an interruption of the light barrier is

cancelled by pressing the START key.
Before restarting the machine after light barrier interruption, the operator
must assure himself, with the help of the mirror on the light barrier
pedestal, that all persons are clear of the area safeguarded.
The operator must take additional steps to eliminate danger that may
arise, for instance, when machining workpieces with unusual contours,
larger sheets or off-center loaded sheets.
Notes on working The technical machine documentation contains vital safety information on
safety the prevention of injuries and potential hazards to life and health. The
& symbol on the left calls your attention to information of this type.
For your safety: This information must be observed without fail!
In addition to the guidelines provided in this manual, the general

regulations governing safety and accident prevention must also be
observed.
1-8 Safety B119E1

4. Overview of dangers
The following overview is a summary of the potential dangers that the
machine may pose to life and health, and of possible injuries. The design
and construction of the machine, coupled with the safety equipment
installed in compliance with EC Machinery Directive 89/392/EEC,
eliminates danger to persons. Any measures that can be taken by the
machine user to reduce any residual dangers are indicated in the
overview below.
• Crushing • Hydraulic punching head Danger of

• Small parts chute injury
Danger of
injury
• Clamps Danger of
• Chipflap injury
• Tool clamping Danger of
injury
Mechanical danger Danger of
injury
• Cutting and severing
• Hydraulic punching head Danger of injury
• Blows
• Transverse rail Danger of injury
with workpiece
• Support table Danger of injury
• Fluids and gases expelled • Hydraulic hoses Danger of injury

under
high pressure • Pressure units Danger of injury
• Parts being ejected • Workpiece Danger of injury
Electrical danger
• Due to electrical contact • Direct contact with Lethal danger
normally live parts
• Indirect contact with parts Lethal danger

that are live when faulty
Danger from noise emission I

• lntheformofhearingloss Whispertools
• Punching/Nibbling Health hazard • Use Softpunch
Wear
andear protection
Danger from materials
Through contact with or by inhaling Toolspray lubricationHealth hazard Uselubricantssparingly
toxic fluids, gases, mist, vapors and Proper ventilation
dust
Danger due to faults or malfunctions
Power supply failure• Drives Danger of injury
Control voltage Danger of injury
Thermal danger
Danger due to vibrations
Danger due to radiation
• Additional precautions to be taken by the customer to reduce the residual danger existing despite the machine's safety
equipment
B119E1 Safety 1-9

1.10 Safety B119E1
Chapter 2
Technology
B119E2 Technology 2-1

1. Introduction
Mechanical cutting pro Punching and nibbling are mechanical cutting processes used in indu
cesses strial fabrication. With these processes, cutouts and contours of any
shape and size (within the working range of the machine) can be pro
duced in flat workpieces.
The workpiece is held by clamps and positioned under the tool by a

coordinate guide. A hydraulically driven punch, available in any shape,
cuts through the material with each stroke.
Tool set A set of tools for punching and nibbling consists of a punch, die and
stripper. The punch may be a single tool, or it may comprise several
separate (multiple) punches.
2. Mechanical cutting processes

2.1 Punching
Definition When punching, the cutter makes one single stroke. The cutout thus
produced corresponds exactly to the geometry of the punch. Elements
such as hole rows and grids, and bolt circles result if the workpiece is
shifted a given distance after each given stroke.
Punches with a bevelled The punches can be divided into two groups: punches with flat cutting
cutting face faces (normal punches) and those with a bevelled cutting face
("Whisper tools"). Such Whisper tools have two significant
advantages:
□ less punching force required for tools of comparable size

□ reduced noise emission when punching
2-2 Technology B119E2

Cutting tools with bevelled surfaces are longer than corresponding
tools with flat cutting faces; consequently, a greater depth of pene
tration is required when using these longer tools. Tools with bevelled
cutting surfaces are available as standard tools for diameters (round)
or lengths (square) of 10.5 mm or greater.
Such shear-cut tools may be used for nibbling materials with a tensile
strength of 400 N/mm2 up to a sheet thickness of 3 mm, and with a
tensile strength of 800 N/mm2 up to a sheet thickness of 2 mm.
Accuracy and shear-cut

The following steps are recommended in order to attain the highest
tools
accuracy when using shear-cut tools:
□ Insert the tool with symmetrical axis in Y direction

□ When nibbling, the shear tip must have contact with material
y
..
Nibbling with shear-cut tools Fig. 10064
Reducing the necessary

The punching force required depends on the tensile strength of the
punching force
material and on its thickness. The amount of punching force needed
can be reduced by following the suggestions given below:
□ use tools with bevelled cutting face (see above)

□ prepunch and finish-punch
A smaller punch initially prepunches the hole, after which the tool
of the required size is used to finish punching. This method
allows holes to be cut for which the existing punching force would
otherwise be inadequate. Because of this prepunched hole,
material flow is not impeded at the finish punching stage, thus
reducing cutting resistance.
2.2 Nibbling
Definition
In the nibbling process, the workpiece is advanced step by step in the
desired feed direction while the punch constantly moves up and down
(continuous stroke sequence). A unique feed control assures that the
workpiece comes to a stop shortly before the punch dips into the
material.
The next feed step commences as soon as the punch is again above
the workpiece surface. Through continuous repetition of this process -
feed release, feed interruption, coupled with constant stroke
movement of the tool - the cutting of the desired workpiece shape is
divided into a score of small individual cuts.
The size of the individual feed increments is determined primarily by
the following factors:
□ type and size of tool in use

□ required quality or roughness tolerance of nibbled edge
Please refer to the programming instructions for specifications on the

roughness tolerance of the workpiece edge when nibbling.
Nibbling speeds The maximum feed step depends on the feed release, and con
sequently the sheet thickness, as well as on the stroke rate of the ma
chine. The speeds possible when nibbling can be derived from the for
mula given below:
a Feed step [mm] a·n

n Stroke rate of ram v = -- [m/min]
per minute 1000
The fact that the cutting process is divided into partial cuts in rapid
succession, using a simple tool, makes nibbling particularly suitable
for the following tasks:
Nibbling application □ Fabrication of cutouts and contours of any size and shape which,
due to the punching capacity of the machine, cannot be made in
one single downstroke of the ram.
□ Production of cutouts that are irregular in shape and for which a

special tool capable of making the cutouts in one downstroke of
the ram would be too time-consuming or too costly.

Nibbling tools Generally speaking, the punching tools of the TRUMATIC can also be
used for nibbling. It is best, however, to use tools measuring between
4 and 30 mm in diameter or length.
Special nibbling tools are available primarily for use in nibbling operat
ions, especially when working with materials that are thicker or of
higher tensile strength. These tools, because of their special
construction and the tool steel used, have a considerably longer tool
life. We strongly recommend the use of these tools. Please refer to
the TRUMPF catalog on "Punching and Nibbling Tools" for further
details.
The tool requirement for one workpiece can often be reduced because
cutouts which are supposed to be punched can also be nibbled.
Besides savings in tool costs, another benefit lies in reduced
production times.

Mild steels
3. Tensile strength Rm of metallic materials
I I Abbfiiiif Mififiilj ? tirililiiU tirililiiffi. }
I <i66i j iij I 11 111i r R111 [N1111111!l Hrri ri 111111!]
J}
i
! UW11119 IJiij ltttt <
9)
Rust and acid-resistant St33 1.00 290- 540 4
steels 35 1
5
St 37-2 1.00 340-510 4
37 2
5
St 37-3 1.01 340-510 4
16 2
5
1•1111lJ••··········
X 7 Cr 13
X 7 CrAI 13
1.4000
1.4002
700
450- 700
575
····· -················
X 10 Cr 13 1.4006 550- 750 650
725
X 15 Cr 13 1.4024 650- 800
X 20 Cr 13 1.4021 650- 950 800
X 40 Cr 13 1.4034 -800 525

X45 CrMoV 15 1.4116 -900 525
X 8 Cr 17 1.4016 450 -600 525
1.4510 450- 600 550
X 8 CrTi 17 X8CrNb17 X
1.4511 450- 600 700
6 CrMo 17
X 12 CrMoS 17 1.4113 450- 650 900
X 22 CrNi 17 1.4104 550- 850 600
1.4057 850- 950 600
X 12 CrNiS 18 8
1.4305 500-700 600
X5CrNi189 X5CrNi 1911
1.4301 500- 700 575
X2CrNi189
X 10 CrNiTi 18 9 1.4303 500- 700 625
X 10 CrNiNb 18 9 1.4306 450- 700 625
X 5 CrNiMo 18 10 1.4541 500 -750 600

X 2 CrNiMo 18 10 1.4550 500 -750 575
X 10 CrNiMoNb 181'0 1.4401 500- 700 625
X 5 CrNiMo 18 12 1.4404 450- 700 600

X 2 CrNiMo 18 12 1.4580 500-750 575
X 2 CrNiMo 18 16 1.4436 500- 700 600

650
2-6 Technology
X 2 CrNiN 18 10 1.4435 450- 700
700 B119E2
X 2 CrNiMoN 18 12 1.4438 500- 700
X 2 CrNiMoN 18 13 1.4311 550 -750 700
1.4406 600-800
1.4429 600-800
Copper and copper
x1;;1m,*1ah I u,1 Mu rl&1i,1'*;r
J r1H1i,1
uu
1 I
}
alloys
(E>v11:fo :
i < •1; 1 7670 P
)
1111r l
) 11:Z01 $!
21
SW-Cu 2.007
6
SF-Cu 2.009
0
F20 . 200- 250 2
1 2
0 5
F22 . 220- 260 2
1 4
0 0
F24 . 240- 300 2

Aluminium and
x1;;1m,*1a I u,1
Mu } r1H1i11
uu
1 I
I
aluminium alloys
i< h r l&1 i1
•1; 1 745 1 ,:.11r :1 i '*;r1 J 1111r P
l
4) :Z 012 $!
1
Al99.8 F1 3.0285 . 100 - 140 1
0 2 2
6 0
Al99.8 F1 3.0285 . 120 - 160 1
2 3 4
0 0
Al99.7 F1 3.0275 . 100 - 140 1
0 2 2
6 0
Al99.7 F1 3.0275 . 120 - 160 1
2 3 4
0 0
Al99.5 F8 3.0255 0 75 - 110 9
. 7 2
F9 . 90 -130 1
2 1
4 0
F1 . 110-150 1
1 2 3
6 0
F1 . 130 - 170 1
3 3 5
0 0
F1 . 150
5 3
2
AIMn1 F1 3.0515 . 120 - 160 1
2 2 4
2.8 Technology B119E2

4. Tables of maximum capacities
4.1 Formulas
These tables of maximum capacities specify the maximum dimensions
permitted for round and square tools with and without a bevelled
cutting face, classified into four tensile strengths, and for varying sheet
thicknesses. If the values for sheet thickness and tensile strength lie
between the ones specified, the next lower value in the table should
be applied. Alternatively, the tool dimensions can be calculated
according to the formulas below:
Maximum diameter for p·x

round tools dmax=
3.14 · s · 0.9 · Rm
dmax maximum tool diameter (round) [mm]

p cutting force [N]
s sheet thickness [mm]
Rm tensile strength [N/mm2]
x shear factor (for tools without bevelled cutting face = 1)
Maximum length of edge

p·x
for square tools
amax=
4 · s · 0.9 · Rm
amax maximum length of edge (square) [mm]

p cutting force [N]
x shear factor (for tools without bevelled cutting face = 1)
Maximum cutting
p
perimeter for irregularly
shaped punches or Lmax=
s · 0.9 · Rm
cluster tools without a
bevelled cutting face
Lmax maximum cutting perimeter [mm]

p cutting force [N]

4.2 Influencing factors
These tables are valid for metallic materials. Especially when
punching non-ferrous materials, heavy strain-hardening may result
and thus require a higher cutting force.
The values given in the table of maximum capacities are standard va

lues which may be affected by the following factors:
□ According to DIN 1541/1543, the sheet thickness may include a

maximum tolerance of +18 %.
□ The tensile strength can reach +12.5 % according to DIN 1623.
□ The necessary punching force is increased by about 4% if the air
gap between punch and die is reduced from 10% to 5% of the
sheet thickness.
□ Lubrication of the workpiece reduces the friction force.
□ The shear factor is based on theoretical calculations and is also
affected by the workpiece properties.
□ The sharpness of the punch
□ Damage and breakage at the cutting edge of the punch
In practice, this means that if all adverse factors are multiplied with
each other, only about 70% of the specified values can actually be
utilized if one wants to make sure that the punch cuts through material
properly.

4.3 Dies
Dies are available as standard dies and reinforced dies up to the fol
lowing maximum dimensions:
R iM 1 a t
·.·.·.·.·.·.·.·.· .·.·.·.·. ·.· .·.·.·.·.·. ·.·.·.· .·.·.·. ·.·.·.·.·.
d t tii s I
·.·.·.·.·.· .·.· .·. ·.· .·.· .·.·.·.·.·.·.···
round: 77 54
dmax [mm] .0 .0
square: 52 38
amax [mm] .0 .2
a/d
aid Side length of square cutout/Inner diameter of die

Standard die Fig. 1394
aid
aid Side length of square cutout/Inner diameter of die

VReinforcing edge
Reinforced die Fig. 1395

I! §imm)ffijy $i g < == g.91zz.-
r iqij $q§jij¢tic:f{q
f ??-91 - §?-C>
==
j ffi . 19 .1:l @NJQQ kN;@ijihfg@ijg§
1 iii 2, iiii g (I g.g1 t -P m,m; ,,.qi t ,,.g mmt
■
=== ===
! ffijy $Qijjij¢tijgJ§ j ffijiflgjg @N?!?QKN- Pii$ 9f §i?i4 (g
()1 11; RJ2 ,.g m,m; 2;;.q mm> 2 rit bi,vi riir!2r9@t , iiJ
===
! gqg ffigy pij $Qqiij¢ ijgJq mi'5UPi9 At?§9 kN• /
4.4 Punches
When using standard or reinforced dies, round and square punches
may be used up to the following maximum dimensions:
junch, 11s1 juncilili ;inf r-

round:
dmax [mm]
ir; I I
76 53
.2 .8
square: 50 38
amax [mm] .8 .0
4.5 Overview of tables

The values in the following tables show the maximum dimensions of
the punches of round and square tools as a function of the sheet
thickness and the tensile strength. The maximum tool dimensions
specified in the "with" columns apply only to tools with an original
bevelled cutting face ("Whisper tools").
This also applies to the shear factor.

Table of maximum
capacities for tensile
strength Rm = 200
N/mm2
wi witho with witho
th ut ut
1.0 3.5 3.5 76. 76.2 50.8 50.8
2
1.5 2.6 1.8 76. 76.2 50.8 50.8
6 2
2.0 2.2 1.1 76. 76.2 50.8 50.8
5 2
2.5 2 0.8 76. 76.2 50.8 50.8
2
3.0 1.8 0.6 76. 76.2 50.8 50.8
3 2
3.5 1.7 0.5 76. 76.2 50.8 50.8
1 2
4.0 1.6 0.4 76. 76.2 50.8 50.8
2 2
5.0 1. 0.3 76. 63.7 50.8 50.0
5 2
6.0 1.4 0.23 74. 53.8* 50.8 41.7
1 7
8.0 1.3 0.16 53. 48.6* 40.9 38.0*
1 8*
* with reinforced die
Table of maximum
capacities for tensile I l l'u rli
strength Rm = 400
N/mm2
r n i t m m u<x• • • •
. ... . .. .... .... .. . .. .. .
with witho with witho

ut ut
1 3.5 3.5 76.2 76.2 50.8 50.8
.
0
1 2.6 1.8 76.2 76.2 50.8 50.8
. 6
5
2. 2.2 1.1 76.2 76.2 50.8 50.8
0 5
2. 2 0.8 76.2 63.6 50.8 50.0
5
3 1.8 0.6 76.2 53.8* 50.8 41.6
. 3
0
b 1.7 0.5 76.2 53.8* 50.8 38.0*
3. 1
5
4 1.6 0.4 64.4 48.6* 50.5 38.0*
. 2
0
5 1. 0.3 53.8* 38.9* 38.0* 30.5*
. 5
0
6. 1.4 0.23 45.7* 32.4* 35.9* 25.4*
0 1
8 1.3 0.16 31.8* 24.3* 25.0* 19.0*
. 1
0

Table of maximum
strength Rm = 600
N/mm2
wi witho with witho
th ut ut
1.0 3.5 3.5 76. 76.2 50.8 50.8
2
1.5 2.6 1.8 76. 70.7 50.8 50.8
6 2
2.0 2.2 1.1 76. 53.8* 50.8 41.6
5 2
2.5 2 0.8 76. 51.8* 50.8 38.0*
2
3.0 1.8 0.6 64. 43.2* 50.8 33.9*
3 7
3.5 1.7 0.5 53. 37.0* 40.7 29.1*
1 8*
4.0 1.6 0.4 52. 32.4* 38.0* 25.4*
2 5*
5.0 1. 0.3 38. 25.9* 30.5* 20.3*
5 9*
6.0 1.4 0.23 30. 21.6* 23.9* 16.9*
1 4*
8.0 1.3 0.16 21. 16.2* 16.6* 12.7*
1 2*

Table of maximum
strength Rm = 800
N/mm2
wi witho with witho

th ut ut
1.0 3.5 3.5 76. 76.2 50.8 50.8
2
1.5 2.6 1.8 76. 53.8* 50.8 41.6
6 2
2.0 2.2 1.1 76. 48.6* 50.8 38.0*
5 2
2.5 2 0.8 63. 38.9* 50.0 30.5*
6
3.0 1.8 0.6 53. 32.4* 38.1 25.4*
3 8*
3.5 1.7 0.5 47. 27.7* 37.3* 21.8*
1 5*
4.0 1.6 0.4 39. 24.3* 30.9* 19.0*
2 3*
5.0 1. 0.3 29. 19.4* 22.9* 15.2*
5 1*
i miii.) shil\
6.0 1.4 0.23 22. 16.2* 17.9* 12.7*
u ness >1.3
1 8*
8.0 0.16 15. 12.1* 12.5* 9.5*
rn 1tmm1••••
1 9*
factor>
x>
Sheet thickness 8 mm: Row-by-row machining is strongly recom mended

if the greater part of the sheet will be punched up.
5. Feed
5.1 Feed per stroke when nibbling

The following recommendations apply to mild steel with a tensile
strength of 400 N/mm2. Any departure from these recommendations
may result in longer machining times or in shorter tool life.
5.1.1 Feed per stroke for round tools

Roughness diagram The size of the feed step depends on the desired roughness. Fig.
0940 indicates approximate feed steps for various punch diameters as
a factor of the required roughness.
R
m 1 i
0. 8 .01,
m n 0 H 8 -12 1s '30 1f"
I> I
-20
I . •• j _ •• ) I .. I IJ '..J
0,7t . Ji
06,f .7- l II ,r11biJ V'-
I
; 8I
a I 5•
i4'1-,f_y
b
-
0,
O 1 22 3 L 5 G 7 B 9 1 m
';·nrrrr,r
C 0 m
0 ,04 .12 .2 ,24 ,28 , . , i
,OB ,1 3 3 4 n
6 2 6 0
RtRoughness [mm]
1 ,••
DPunch diameter
[mm] EFeed step [mm]
Rt coarse
Rt medium E-----------
Rt fine
Roughness diagram Fig. 0940
The minimum feed step can be calculated according as follows:

EF Too
ee l d
D
d iam
pe
r s ete
tr o r [
ke mm
[m ]
m
]R
tR
ou
gh
n
es
s [m
m
]
Linear feed The linear feed per stroke can also be established as follows:
Linear feed Fig. 0738
Circular feed The circular feed per stroke can be established as follows.
c
c
B119E2
Fig. 0739
] ]
m mm
[m s [
ss iu
ne rad
gh th m]
ou a m
tR o l p e [
] R o dg
m 1T e e
[m ] R iec
ke mm kp
tr o r [ o r
r s ete e w
pe h
d iam f t
ee l d s o
EF o diu
o
DT 2Ra
R
Circular feed
Technology
2-16
5.1.2 Feed per stroke for square
or rectangular tools
The following rules of thumb apply for the minimum and maximum
feed steps:
Minimum feed step
Minimum feed step Fig. 3678
Note that half the punch must have contact with material in X or
Y direction.
Maximum feed step

LL
en dth n o
BW irec
gt of f f
D
h
i tio
of p u n e d
I
p u ch
nc [m
h
[m m]
e
m VR
]
I
fil
L.
/3
1J
-
qr
VR
.
-
Maximum feed step
L
LL
en
thg
[
of
pu
nch
[m
m
]
l
2m
m
5.1.3 Feed per stroke with slitting
tools, oblong tools or tools with
corner radius
The minimum and maximum feed steps allowed with these tools can
be calculated as follows:
L Length of punch [mm]

R Radius of punch [mm]
The entire width of the punch must always have contact with the
material.
For cutting strips, a minimum width of about 10 mm is recom
mended.
If the border is less than 10 mm wide, the strip of material may
become warped, subjecting the tool to shearing forces and thus
reducing tool life.
5.1.4 Punch dimensions recommended for

nibbling
The following dimensions, relative to the material thickness, are re
commended for nibbling with round and square punches:
::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
d Punch diameter
a Length of edge Riirlij
i P46iti> Jm Yiri PY ?
of square punch
1 M
· · · · · · .···.i·[.A··.·········.A········.··t.1·.i··.··.··.··.···.··.··.··.··.··.··.··.···.··.··I..
[·M·····< ······i···r···.1i. · ······[·········1·················t·········H1
.· .· . ·. ·. ·
>··
.. m m ..... ..................... >m m •
... ..... .......
<m m .. ..... .................... < m m .................<

.... .....
8 1 12 12 12
2
6 1 12 12 12

6. Slotting tool (Option)
General notes
Slotting is a double-edged shearing process where a continuous ste
pless cut of a given length is achieved. Owing to the tool design, the
resulting chip is not cut off during while slotting. The tool penetrates
the material on the first stroke. Due to the curved form of the cutting
edge, the chip rolls into a spiral on the subsequent strokes. The
maximum spiral diameter, dependent on the sheet thickness, determi
nes the maximum cutting length. At the end of the cut, a deep down
stroke released with M822 cuts the chip off.
The tool set consists of a punch, the cutting edge of which has a
curved polyurethane stripper, and a special die with a groove.
Di
re
cti
n o
of
w
I
or
kp
ie
ftD
ce
fe
ed
A "
'--
••
Slotting tool - mode of operation Fig. 4669
Punch sizes
The following punch sizes are available for parting:
2. x 30 mm
5
5 x 30 mm (most commonly
used)
1 x 30 mm
0
Tools of size 5 x 30 mm and 10 x 30 mm may be used for a sheet

thickness between 0.5 and 2.0 mm, and tools 2.5 x 30 mm for sheets
measuring between 0.5 and 1.5 mm.
Slotting feedrate A feedrate of 5 mm per stroke is recommended. Other feed values
have an unfavorable effect on the cutting quality.
Maximum length of cut The maximum cut length depends on the sheet thickness. The
following standard values apply.
0. 1500
5
0 1000
.
8
1 800
.
0
1 500
.
5
2. 350
0
7. Coordinate system, axes direction
The TC 500R is used for machining flat workpieces. The two linear
axes X and Y form a Cartesian coordinate system (Fig. 3679).
•
X •
Jr
,x.
Cartesian coordinate
system
' Fig.
3679
+YK
It is advisable to set the zero point of the coordinate system to the bot
tom left corner in all drawings (Fig. 1430).
+
0
Y
N
l
+
i
0
0
+
' 0
,
e
+
n
I
..
--
.., .
'--
'--
+1
'--
00 ,
-
+1
V
50
'
+2 0
0
-
- -
+
- X
Coordinate system Fig. 1430

The machine design is such that the workpiece moves while the tool
remains stationary.
The programmer, however, must base the program on the premise of

a stationary workpiece and a moving tool; therefore, he programs the
path "traced by the tool on the workpiece".
This means that, for the correlation between tool/workpiece movement

and the movement of the coordinate guide:
□ the coordinate guide (K) moves in +XK direction (towards the

right as viewed from the front of the machine) if the tool (W)
describes the path marked +Xw relative to the workpiece (Fig.
3679)
□ the coordinate guide (K) moves in +YK direction (towards the

rear as viewed from the front of the machine) if the tool (W)
describes the path marked +Yw relative to the workpiece (Fig.
3679)
The X and Y coordinates may be programmed in either metric (G71)

or inch (G70) mode.

8. Tool magazine
8.2 Magazine stations

The tool stations in the magazine of the TC 500R are located in fixed
positions. The following number of tool stations are available in the
magazine:
20 for working range Y1300 with standard clamps

21 for working range Y1300 with retractable clamps and
for working range Y1600 with standard clamps
23 for working range Y1600 with retractable clamps
The distance between the individual stations is 130 mm. At least two
of the magazine stations for working range Y1300 or three for working
range Y1600 must be occupied by standard clamps.
Standard clamp Standard clamps can be located at any of the available magazine
positions stations; however, the selected clamp positions must assure that the
sheet is held securely.
The following clamp positions are recommended for working range

Y1300:
□ If two clamps are used: Clamp positions 7 and 14 are
recommended.
□ If a third clamp (option) is used: The clamps can be set as
desired.
Retractable clamp Option "Retractable Clamps" consists of 6 retractable clamps which

positions allow the entire sheet to be machined without any residual strips.
These clamps are located at fixed positions:
Clamp2 Mag. station 6 Mag. station 5
Clamps Mag. station 16 Mag. station 15

TC 500R with TRUMA The clamps must be fitted with sensors if a TRUMALIFT SheetMaster
LIFT SheetMaster 1300 / 1300 / 1600 is installed.
1600
2 standard clamps 2 sensors
3 standard clamps and more 3 sensors
Retractable clamps Sensors on clamps 1, 2 and 5
The clamps close if at least 2 sensors signal contact with the sheet.
The sensor zero stop serves as the sheet stop in X direction.
Working range Y1300

with standard clamps s
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
MMachine datum
SPunching tool adapter
Here, standard clamps are located at stations 5 and 16
Position of tool magazine stations for working range Y1300 Fig. 6137
Working range Y1600

with standard clamps
M
1
2 achi ing ard
3
M n sta
f4 6 7 f84 tum dapte ps ar

4 f ne d ool cla
M ch n
SP r e ,
54 a a m
f4 9
u
He
-•-
-
f4 1 112 1
-
10
r-
t
1f4
f4 3 1
d
'
s
f4 5 1
r e lo
f4 6 1f74
4
1
lf4 18
ca
f4 2
te
d
f4 21 f
at
19
st
ati
f4 f4
on
s5
f4
4
,1
f4
0
an
d
16

Working range Y1300
with retractable clamps s
..
!
M
1 2 3 4 5 6 7 6 9 10 11 12 13 14 15 16 17 16 19 20 21
MMachine datum
Working range Y1600 s

with retractable clamps
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
MMachine datum

Station 1 15mm -60 mm 225mm 95mm
Station 2 145 mm 70mm 355mm 225mm
Station 3 275mm 200mm 485mm 355mm
Station 7 795mm 720mm 1005 875mm
Station 8 925mm 850mm mm 1005
Station 9 1055 980mm 1135 mm mm
Station 10 mm 1110 1265 mm 1135 mm
Station 11 1185 mm mm 1395 mm 1265 mm
Station 12 1315 mm 1240 mm 1525 mm 1395 mm
Station 22 - 2540 mm 2825 mm 2695 mm

--
Station 23 2825 mm
2955 mm

8.2 Dead area of standard workpiece clamps
Owing to the geometric dimensions of the tool adapter and workpiece
clamps, machining is impossible in the area directly adjoining the
clamps. This so-called "dead area" must be factored in when pro
gramming to ensure that all machining operations take place outside
of it.
Make sure that the clamp dead area is not violated when approaching
a position in its immediate vicinity.
........
........
. .........
..................
F
/ .........................
..
97 97
FIncorrect approach
RCorrect approach
PStandard clamp
Fig. 3677
A clamp dead area of 85 mm in Y axis is effective for standard

clamps when positioning with the clamps open, e.g. when repositio
ning.
Please refer to Chapter 9 "Multitools" in the programming manual for
details.

Retractable clamps Option "Retractable Clamps" enables machining unimpeded by dead
areas. For this purpose, the dead area cam must be active and at
least 3 clamps must hold the workpiece. If this cam is not active, a
dead area of
□ X axis: 226 mm
□ Y axis: 77 mm
around the respective clamp must be taken into account.
A repositioning position 88 mm in Y must be selected for retractable

clamps with inactive dead area cam. In the case of retractable clamps
with the dead area cam active, repositioning is possible in any Y
position -7 mm.

9. Working and overshoot ranges
9.1 Working range V1300

The machine has a working range
□ in X direction of 2500 mm
□ in Y direction of 1250 mm
Overshoot range with This working range can be overshot

standard clamps
□ in X direction from -35 to 2535 mm

□ in Y direction from - 7 to 1280 mm
□ in -Y direction during tool change up to -161.5 mm
2500mm
I
L
E '
E
0n
E
E
0
en
N
35mm 35mrr
+-
E
rE
vi , '!
iE
'························2··
Ul
;;;
MNP Machine datum

Overshoot ranges Fig. 6138
A reduced working and overshoot range may result when using

Multitools with special punches. Please refer to Chapter
"Multitool" in the programming manual for details.

retractable clamps

60
m
m
E
ti
E
!
25
0 0m
M
m
NP
;--
.
M
NP
M
ac
hi
J
E
en
E 'l
"
da
E
tu
E --
r
m
40
m
m
E
E
0
-
lQ
:::

9.2 Working range V1600
The machine has a working range
□ in X direction of 3000 mm
□ in Y direction of 1600 mm

standard clamps and
retractable clamps

L
0 E
EO
L
30
00
35
m
rim
m
M
NP
E
E
"'.
M
E
N
I'-
E
P
M
ac
-
hi
ne
atd
um
ill
►
"
'
8-5
m
E
m
0
E
0
lO
+-
-
'I'

10. Stop pin
The round pin which serves as the workpiece stop is located to the left
of the tool adapter, as viewed from behind the machine.
The distance from the edge of the stop pin to the center of the tool
adapter is 680 mm; the distance from the center of the pin to the
workpiece clamp is 110 mm.
The pin is 20 mm in diameter.
C
68
0
0
T " ""
""
T"
Tr nte
an r
1
Ce
sv of
er to
se ol
ra ad
il w ap
2
ith ter
m cSt
ag op
az
3
in pin
e
st
ati
o
ns
4
(st
a
---
nd
ar
---
d
-b
5
c la
--
m
-
p
at
st
6
ati
on
2)
7
a
Fig. 3676
The TC 500R is equipped with a swivel sensor zero stop if a

TRUMALIFT SheetMaster 1300 / 1600 is installed.
Chapter 3
Installation Conditions
TC SOOR
1I
mmi IiiMIi t ii Ill 1!111111 jl
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B119E3 Installation Conditions - Version 12 3-1
TRUMPF
Contents
1. Installation Site . 3-3

rn 1,1 i' I 1. . .
. 3-3
[;,; 1 Space
requirements
. 3-3
1.2 Floor requirements . . 3-3
1.3 Weight distribution . . 3-6
[I] 2.
2.1
2.2
Power Supply......................................................................3-7
Electric Network........................................................................3-7
Notes on the Isolating Transformer..........................................3-8
Current loads, current intensities............................................. 3-9
2.3 T eleservice.................................................................................... 3-9
2.4 Network Connection . 3-9
3. Pneumatic Connection....................................................3-11
B 4.
4.1
Oils and Lubricants. . . .
Oil for the hydraulic system
3-13
3-13
4.2 Lubricants for spray tool lubrication 3-14
4.3 . Materials ..... 3-14
5. Machine Transport . . . . . . . . . . . 3-15

5.1 Work to be performed by the 3-18
al
5.2 customer . TRUMPF service work 3-18

......... .
6. Planning Aid.....................................................................3-19
3.2 Installation Conditions - Version 12 8119E3

1. Installation Site
[oJ [ ]
1.1 Space requirements
The layout of the individual system components and the space
required for standard installation are specified in the respective
installation plan. Also indicated in the plan is the space required for
opening the doors of the control cabinet.
A customized installation plan is needed for non-standard system

configurations.
1.2 Floor requirements
Floor quality Concrete plate (825), thickness 200 mm.

Detailed specification, see DIN 1045.
Evenness Floor must be as level as possible, maximum

difference in height 10 mm over the entire installation
area
(see installation plan)
Installation area No expansion joints, cracks etc. between
the load support points
Sealing Floor must be oil-tight (clean water codes)
1.3 Weight distribution

Structural stress
The load bearing capacity of the floor must be tested by a structural
analysis
stress analyst prior to installation. The weights of the individual system
components and the load at the points of support are indicated in the
table below.
If installation is on 4 wedge mounts, an additional dynamic load of

max. 1500 kg is exerted on the floor at support points P1 and P2. In
semi anti-vibration installation, the floor is subjected to only about
20 % of the dynamic forces.
8119E3 Installation Site - Version 12 3.3

I·t,cBp
-
Machine P1:2425 P1: 3020r Weight supported on P2:3020 I 4
I
wedge mounts:
P3:3880200 x 200 mm each, or P4:3880on 2
wedge mounts and
I: 138002 air cushions (option):
Y1300:
370 x 370 mm Y1600:
500 x 500 mm I Edges support main
Control 555 555
cabinet with I load
panel
--
Operating panel 100 Edge bears main load
100
1
co 0 0 0
"CO' 0,,, 0,,, "CO'
3050
II)
,,,
Ill
0 0
Lil
0 0
374_. @}
0-+----------....--.-----,.----------
,,,s
CY'JN
"'(0
N
1435 --'---+---'
Weight support (Y1300) Fig. 3450
3.4 Installation Site - Version 12 B119E3

TRUMPF
I 00
0
" "
ID
Lt>
0 00
0""
Lt> ID
3650
0 0
0
C\I
... 0 ...
0
0
394---
0
o-+-------------.---+---,1
}
1435
Weight support (Y1600) Fig. 8051
-
B119E3 Installation Site - Version 12 3.5
I'' '.,:,U,cac,I
TRUMPF
1.1 Ambient conditions

Ambient temperature
An ambient temperature between +10 °C and +40 °C is recommended
for machine operation. The temperature must not be allowed to drop
below +4 "C when the machine is off.
Control cooling
The control is cooled by means of internal ventilation in the housing.
The components are thus well protected against dust and dirt.
The heat from the control housings is normally dissipated by means of
external heat exchangers with fans drawing in the air and blowing it
along the cooling fins. Care must be taken to avoid excessive air
contamination in the intake range of the fans behind the control cabi
net since dust on the cooling fins reduces the cooling effect.
Humid rooms are not suitable for the operation of control systems
since moisture in the air can cause contacts to corrode, resulting in
control errors.
Cooling the operating The operating panel is cooled with the help of two fans. Filter mats
panel prevent dirt particles from getting into the operating panel.
Tropical version The standard version of the machine is designed for ambient
temperatures up to 40 °C. For temperatures up to 45 °C, an external
chiller unit must be connected for the hydraulics.
3.6 Installation Site - Version 12 B119E3

2. Power supply
The equipment is wired for the following rated voltages:
460 V +10 %/-5 % 60 Hz±1 %
Install an isolating transformer if the rated voltage varies from 400 V or

460 V respectively. 1
Power supply to the system requires a four-pole connection with
copper cables (L1, L2, L3 in the right rotary field; PE).
The mains supply on the control cabinet of the machine is done as
shown in the layout.
Specification: Specification: Execution as per Execution as per

Execution as per four-pole VOE 0100 VOE 0100
DIN EN 60204-1/ copper cable Part 430 Part 540
(L1, L2, L3, PE) (IEC 364-4-47) (IEC 364-5-54)
2.1 Electric Network

The machine may not be connected to a network shared by welding
machines (temporary voltage peaks). Relief can be provided in such
cases, and also if the network is heavily loaded, by means of a direct
line straight from the interconnecting station.
Fault current circuit

Use type B only when fault current circuit breakers are required on the
breakers
network side for protection in the case of direct or indirect contact.
See EN 50178 Pt. 5.2.11.2 (VOE 0160, April 1998 edition)
If the machine's leakage current is larger than the set fault current,
when using a fault current circuit breaker, install an isolating
transformer to separate the machine from the mains. See EN 50178
Pt. 5.2.11.1 (VOE 0160)
Network types IT or TT or unsymmetrical networks (one phase grounded) require
connecting the machine via an isolating transformer.
1 If the rated voltage is 380 V or 415 Vat 50 Hz, determine the network tolerance. If the tolerance is between 360 V and 440
V, an isolating transformer is not required.
G
B119E3 Installation Site - Version 12 3-7
TRUMPF
Notes on the Isolating Transformer
Observe the following notes when the machine is equipped with an

isolating transformer:
• The power cables leading to the isolating transformer and from the
isolating transformer to the machine's control cabinet can be
guided into the isolating transformer via PG 48 screw connections
from the sides and from the back (top and bottom).
• The power cables must be provided and laid by the customer.
• The customer must define where the isolating transformer is to be
installed.
• The isolating transformer's dimensions are:
• length: 800 mm
• width: 600 mm
• height: 1200 mm
• The isolating transformer must be set up in such a way that it
remains accessible via the hinged door on the front (door with
name plate). Maintain a safety distance of 800 mm. The minimum
sp
ac
e
at
th
e
sid
.
es
an
d
th
e
.
ba
ck
0
is
0
10
iD
.
0
80 mm
0 .
►
1I
so
L
la
tin
g
tr a
L.
ns
.
fo
c
8o
rm
I
er
'
2S
1
af
et
y
di
st
an
ce
+
-
I
_J
Space requirements of the isolating transformer Fig. 22793
• The isolating transformer is subject to the manufacturer's

documentation: series transformer MD 30000, by Roller und
Fischer, mat.-no.: 142587. The documentation is available in
German, English and French.
TRUMPF
B119E3 Power Supply - Version 12 [IJ 3-8

2.2 Connected loads, current intensities
TC 500R connected
load at a frequency of j approx. 17 kVA
50 Hz TC 500R with approx. 19 kVA
SheetMaster
I +6 kVA
Tropical chiller unit
for hydraulics
Maximum permissible voltage I 35 A
interruption
(at 400 V or 460 V
respectively)
Max. permissible See also EN 60204, Part 1, Pt.
interruption of the rated 4.3.2, Alternating current supply
voltage
Average power requirement approx. 7.2-8.2 kW/h
2.3 Teleservice
TRUMPF provides the following interface in the machine's control
cabinet:
Interface for telephone connection (tele-diagnostics) via an analog
modem: RJ11 plug with telephone adapter for customary telephone
socket (e.g. in Germany: TAE6-N-coupling).
The customer must arrange for the following tasks to be carried out:
Installation of a telephone socket for an analog modem on the
machine's control cabinet by the relevant telephone company. A
digital connection must be converted into an analog connection by
means of a converter.
The modem must be accessible with a direct-dialling number.
Otherwise you will need a separate line.
2.4 Network Connection

For the network (programming system), TRUMPF provides the
following interfaces in the machine's control cabinet:
RJ 45 plug for customers with Shielded-Twisted Pair network wiring.
If several machines are connected to the network, this requires a

personal hub (network distributor). This is in the machine's control
cabinet and must be equipped with alternating voltage by the
customer, as the distributor must also function when the machine is
switched off. Voltage supply must be carried out as described below:
B119E3 Power Supply - Version 12 [I] 3-9

TRUMPF
• Voltage supply (except for USA and Canada): 230 V with earthed
socked or in accordance with the country's norm. Earthed coupling
is supplied with the machine.
• Voltage supply in the USA and Canada: 115 V with socket in
accordance with US norm.
Concerning the rated voltage and frequency, the tolerances as

described under 2. Power Supply apply to both power supply options
when using a personal hub (network distributor).
3-10 T Power Supply - Version 12 B119E3

3. Pneumatic Connection
0 Either flexible hoses or rigid pipes can be used for supplying

compressed air to the machine. These supply lines must be installed
in the floor.
Minimum nominal diameter of DN9

lines
Length of ring max. 50 m (due to
conduit condensation)
Diameter of ring min. 1" (26

conduit mm)
Length of connection line from max. 5
ring conduit to instrument m
panel
Max. compressed air
consumption (with approx. 25 Nm3
repositioning cylinders) /h
Max. compressed air
consumption (without approx. 8
repositioning cylinders) Nm3 /h
A filter-lubricator (maintenance) unit must be provided by the

customer to assure that the compressed air at the tapping point meets
the following requirements:
Free of condensate Cooled to +7 ·c 5 Use a cold dryer

(condensation pt)
Free of dust Max. particle 4 Air filter at the intake side

size:
15 µm
Max. particle
density: 8
mg/Nm3
Free of oil Max. oil content: 4 Oil-free screw compressor

5 mg/Nm3
Compressor A suitable compressor must be installed if the compressed air supply

is not adequate. Due to the risk of condensate build-up, the maximum
distance between the compressor and the machine should not exceed
50 m.
B119E3 Pneumatic Connection - Version 12 [Q] 3-11

3.12 [g Pneumatic Connection - Version 12 B119E3
TRUMPF
4. Oils and Lubricants

The customer must make arrangements to have oils and lubricants
ready before the machine arrives.
4.1 Oil for the hydraulic system

The machine is shipped with the hydraulic tank filled. The hydraulic oil
used is SHELL Tellus Oil D046.
l\l ::jl;:iiilll,9
SHELL-Tellus Oil DO 46I HLPD / ISO VG 46 max. 138 Hydraulic unit
l
'4- -
MOBIL DTE25 HLPD / V 46
1- 1i.
I max. 138 Hydraulic unit
11
T8
(only for the USA) ISO G
Other hydraulic oils are prohibited!

On the TC SOOR, the hydraulic oil also lubricates the C-axis
worm gear.
t:C\ Please refer to the maintenance chapter in the operator's manual for
information on maintenance on the hydraulic unit.
B119E3 Oils and Lubricants - Version 12 E]

3-13
4.2 Lubricants for spray tool lubrication
., ;
fW
jiJ
Mild steels TRUMPF punch and nibble oil SRH/5 (non- I 2,5
Stainless and acidresistant steels chlorinated) available in the following container sizes:
Spray can (ldent. No.
111309) 1 kg tin (ldent. No.
111310)
10 kg tin (ldent. No. 111311)
Aluminium alloys an non-ferrous metals I Akamin (from Wisura, ldent. No. 061461)
In addition to the aforementioned oils, non-corrosive synthetic cutting agents or coolants can also be used for
spray lubrication. Cutting agents containing solvents or agents which cause corrosion of rubber seals or PVC
hoses are not suitable for this application.
4.3 Materials
Two sheets must be provided for machine inspection:
• 1000 mm x 1000 mm
• Ust 12.03 (DIN EN 10131)
• s = 2.5 mm
3-14 B Oils and Lubricants - Version 12 B119E3

TRUMPF
5. Machine Transport
All machine components must be examined upon receipt for damage
incurred during transit. Visible transport damages must be recorded
on the bill of lading and counter-signed by the truck driver. Hidden
transport damages must be reported to the insurance company and to
TRUMPF within 6 days, at the latest.
The customer must make the necessary arrangements and convey

the machinery from the truck to its final installation site.
@
Such matters as the transport path to the final installation site should
be clarified well in advance of the machine's arrival. In particular,
gateway dimensions, tip-over heights, cable rack heights, the floor
capacity to support armored (heavy-duty) rollers etc. must be
examined.
Remember to take the machine dimensions (as indicated in the
installation plan) into account in your planning!
Machine component
dimensions
Control cabinet 1310 1010 22

45
Operating panel 1200 8

0 14
60
0
Accessories and
handling aids • Crane truck for off-loading the machine. A crane truck with a
hoisting power of at least 80 t is recommended. If on-site
conditions necessitate a greater lever arm, use a crane truck of
higher hoisting power
• with Form C shackle, nominal size 20 (DIN 82101)
• with the customary chains (e.g. oval suspension link) and
transport belts
• Fork lift (carrying capacity min. 3 t) for transporting the accessory
units
• Hall crane (carrying capacity min. 20 t) for transporting the
machine or
• Armored (heavy-duty) rollers (1 guide and 2 rigid rollers), each with
a carrying capacity of min. 10 t) and
• At least 2 hydraulic jacks (min. 10 t hoisting force each, min.
clearance height: 30 mm)
• Hoisting iron (1 m) and extension
B119E3 Transport - Version 12 3-15

M
00
IJ:')
co
Crane eye of the machine Fig. 26535
Transportation of the machine by means of gantry crane Fig. 24519
3
Sh val
ac
2O
kle
su
sp
en
sio
n
lin
k
3C
ra
ne
ho
o k
3-16 Transport - Version 12 B119E3

Shackle Fig. 26515
lii:l
B119E3 Transport - Version 12 3-17
TRUMPF
5.1 Work to be performed by the customer

Off-loading the machine
• Using a crane truck of sufficient carrying capacity, off-load the
from the truck machine from the truck.
• Form C shackle, nominal size 20 (DIN 82101) required for the
machine transport eyebolt.
• Remove the wooden beams from the machine legs while the
machine is suspended from the crane.
• The control cabinet can be transported via fork lift directly from the
truck to the machine installation site.
Conveying the machine • Transport the machine on armored rollers from the yard into the
from the yard to the factory hall
installation site • To continue to the installation site, either a hall crane of sufficient
carrying capacity or armored rollers can be used.
Erecting the machine at • If armored rollers are being used, hydraulic jacks will be needed to
the installation site set the machine down and to align it at its final site.
• Using the hydraulic jacks, raise the machine and slide the wedges,
or wedges plus air cushions (option), beneath it.
• The levelling screws of the wedge mounts must point outward.
• In the case of anti-vibration installation, attach the air cushions with
screws to the front machine legs (valves must be accessible).
• Do not move the machine across the floor once the air cushions
are in place!
The quality of the floor at the installation site must meet the
requirements stipulated in these installation conditions.
5.2 TRUMPF service work

Machine levelling
Machine levelling and commissioning is undertaken by TRUMPF
service engineers.
Machine start-
The machine is started up by a TRUMPF service technician. Start-up
up
comprises setting up the individual components of the system
according to the installation plan as well as providing some initial
training and checking that the machine is in perfect working order.
3-18 Transport - Version 12 B119E3

6. Planning Aid
The checklist below provides an overview of the work and
preparations to be undertaken by the customer.
For details, refer to the corresponding sub-sections in the installation
conditions.
15 weeks Personnel Designate a person to coordinate the

and
preparations for receiving the machine
training
Appoint the operating and maintenance
staff, the programmers and enroll them in
the necessary training courses.
14 weeks, Installation site Decide on the final machine site. Allow
I "'
but no later than week ... for space requirements as specified in
the installation plan.
w@·. Examine the floor characteristics (floor
(._
quality, evenness, oil-tight floor without
expansion joints).
Keep in mind the machine dimensions

and weight.
Do the ambient conditions meet

specifications (room temperature,
exposure to sunlight)?
Examine the transport route

(gateway dimensions, tip-over heights,
cable rack heights, room to negotiate
around corners etc.).
12 weeks, Power supply Install the electrical connections at the

but no later than week ... installation site. The line cross-section
and fuses must conform to local
[I]
regulations.
Arrange for work required to be done on

the tele-service.
B119E3 Planning Aid - Version 12 3-19

TRUMPF
12 weeks, Compressed air Install the compressed air supply at the

but no later than week ... installation site (line size, purity, air
IQJ
consumption).
4weeks, Oils and lubricants Stock up on the following:

but no later than week...
lubricant • Spray tool
4weeks,
B
Transport gear Arrange for the necessary transport gear
but no later than week ... to be available and ready in time.
&_
4 weeks, Inspection Arrange for two sheets to be kept

but no later than week ... workpiece ready for machine inspection:
• 1000 x 1000 mm
• Ust 12.03 (DIN EN 10131)
• s = 2.5 mm
3.20 Planning Aid - Version 12 B119E3

Chapter 4
Description
B119E4 Description 4-1

1. Technical specifications
Max. workpiece weight: 150 kg (Y1300)

230 kg (Y1600)
Space requirement: 6900 x 5800 mm (Y1300)

7900 x 6300 mm (Y1600)
900 1/min (Y1300)

780 1/min (Y1600)
Max. sheet thickness: 8mm
Max. punching tonnage: 220 kN
ca. 11050 kg (Y1300) ca.

13800 kg (Y1600)
2200 mm
Max. punch diameter: 76.2 mm
90 m/min
60 m/min
108 m/min
360'/s
Positioning accuracy
. +/- 0.1 mm
Repeatability••:
. +/-0.03 mm
TRUMPF CNC contouring control TRUMAGRAPH CC220S
ca. 17 kVA / 50 Hz
ca. 19 kVA (with SheetMaster) ca. 25
kVA (with TRUMATOOL) 8 Nm3th at
6 bar
Tool change time: Number ca. 1.5 - 5 s

of tool stations: 20 (Y1300)
21 (Y1600)
Number of clamps: 2, 3 or 4 optional
* The degree of workpiece accuracy depends on the type of workpiece, its pre-treatment,
material thickness, size and position of the sheet in the work area.
** Measured over a length of 1 m, in accordance with VDI/DGQ 3441
*** Including safety zone
**** The technical specifications will vary if Option "Retractable Clamps" is installed
4-2 Description B119E4

Fig. 4580
45
3
10
12
14
Machine sub-assemblies
11
18
t
ar
St
r,
er rie bl
e
rri ar ta
ba tb p
17
ht i gh ro
lig L ) D
ty h: on e
fe itc pti tics in
az
13
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Fo ke um ste ar m
pti buc Pne t sy e
10 (O in
ip nt us l
11 Ch me xha with em
g e t
se hip ail ys
13 C s r lic s
os u
, 14 Cr dra
on l Hy
Sub-assemblies
ad pti oo 15
he (O r) T 16
ng rs e 17
hi de a s t
nc lin M 18
pu g cy eet to
p
lic
9
ni
n Sh le
au ab
2.
dr itio ith n t
Hy os d
w tio ith
p
Re nda
r ica t w itc
h
br i ne is w
st
a y lu
ab el ax ot s
ra h c C
2 sp t c p an ary e Fo
i l ot hut ps
Sw ntro n R
i sc m
3 Co p p art e cla
o p c
4 St all pie
5 Sm ork
6 W
7
8
9
16

2.1 Machine Frame
4 2 1 3
- :.-:- - ""!!!.
Machine frame 3 Punching head

2 Coordinate guide 4 Work support table
Machine frame Fig. 3823
The machine frame is C-shaped; this design makes the frame especially
resistant to bending and torsion forces and enables it to compensate for
spring-back and transverse forces.
As a standard, the machine is installed on wedge mounts (option: anti
vibration installation).
In the throat of the machine frame, the coordinate guide moves the
support table under the punching head.
Brush panels mounted in the area of the die adapter serve to minimize
workpiece scratching during processing.
4.4 Description B119E4

2.2 Coordinate Guide
Bearing bracket3Guide rail Eccentric bolts with roller

2
bearings
Coordinate Guide Fig. 2634
The coordinate guide is located in the throat of the machine. It guides the
workpiece (held by the clamps) under the punching head.
Longitudinal and transverse guides are designed as closed dovetail
ways. The longitudinal and transverse rails supported on roller bearings
are hardened and ground.
The bearing points are covered and the guide rails are fitted with dirt
wipers to prevent contamination.
The coordinate guide is driven in X and Y direction by maintenance-free
AC servo motors.

2.3 Removal of workpieces and scrap
-- - - - - - - - - - - - - - - -+ ----------------
I I
:--- !L,
3 ---j
4
-- _j_
5
Small parts chute

' 4 Workpiece
2 Light barrier (option) 5 Die
3 Fixed chute
y
Removal Fig. 3821
Parts can be removed
□ through the programmable small parts chute (1)

□ through the fixed chute (3)
□ manually.
Scrap can be
□ removed manually
□ cut up
□ pushed out through the fixed chute (3)
Workpieces and scrap can be routed to corresponding containers on the

chip conveyor.

Chips and scrap are drawn into the console (die base); from there they
are dumped by opening the chip flap, with the help of the side channel
blower.
Finer chips enter the filter unit (4) of the side channel blower (1) and are
retained there.
1 4 3 2
Sid ffle
2
e
M
ch
u
an
ne
r
l
bl
ow
er
3
4
Fla een
ng
Sc
e
r
an
d
fo
a m
m
at
er
ia
l
fil
te
r
Side channel blower Fig. 3774
A detailed description of the removal strategies and handling of special

cases is presented in the workbook for manual TC 500R programming.
Co it
2
nt
un
ro
l
St d
rip
ro
pe
r
4
3
4
Pu ap
nc ter
ad
Ra
h
2.4 Punching Head

Punching head Fig. 2859
The ram moves up and down hydraulically in the punching head in

response to ram control signals.
\"--.
.\\
Key components of the punching head include:
Control unit
Here the required hydraulic pressure for punching is released by
switching chambers.
Ram
The pressure is transmitted from the ram to the workpiece through the
up-and-down motion of a tool.
Punch adapter The required tools (punch, stripper and alignment ring) are loaded into
the punch adapter with the help of the tool magazine.
Repositioning The workpiece can additionally be fixed with repositioning cylinders.
cylinders {option) These cylinders are used to hold the workpiece down during the
repositioning procedure when working with excessively long sheets.
The ram assumes different positions (heights) as programmed (M code)
The following heights are differentiated:
Uppermost height For removal of good parts and scrap and for bypassing flanges and
existing farmings.
Forming height Forming work is possible at this height.
Tool change height This height is assumed if a tool change command is in effect.
Working height for The working height for normal flat punches is set according to the
normal punches programmed sheet thickness.
Penetration height The punch penetrates into the die in accordance with the length of the
tool.
Working height for If softkey SHEAR-CUT YES (Whispertool) is activated before the control
shear-cut tools queries the tool table, the working height of the ram will be compensated
{Whisper Tool) upward.
Working height for The working height is generated automatically when a Multitool is loaded
Multitool into the tool adapter.
{option):
Please refer to the Programmer's Manual for further details.

2.5 Workpiece Clamping
The workpiece is held in place by 2 hydraulically actuated clamps (option:
3 or 4 clamps). The clamps can be set to any of the 20 stations (Option:
21). The stations should be so selected as to assure that the workpiece is
securely clamped.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Working range s Tool adapter

X2500 1-20Tool M Machine zero
point
magazine
stations
Workpiece Clamping Fig. 6137
Here, the clamps have been set to stations 5 and 16.
SheetMaster
No clamp may be present in station 1 if a SheetMaster is installed.
installation
If a SheetMaster is installed, certain clamps and the stop pin are fitted
with sensors.
Location of the sensors
With 2 clamps
With 3 clamps
Q
With 4 clamps
Qs Q Q □
Location of the sensors Qs sQss s
s Fig. 7235
D Qs
If 3 sensors are present, signals must be received from 2 sensors to
trigger Enable.
If more than 3 clamps are present, the locating edge of the non-sensor
clamps is offset about 1 mm to the rear.
2.6 Rotary Tool Adapter

Top and bottom tool adapter (i.e. punch, stripper and die) are rotatable
and aligned axially parallel. They are driven separately via switched mode
direct current motors (AC-servo drives).
M
2
ot ter rive
ad otar
or
3
, u ota , bo
a
R
p yd
pp
er y dr om
R
to
ol
r tt
ive
,t
op
4
5
6
Ra
m
Di
e
ad , low
M ap
ot te
a
ad
pt
or r
e r r to
e
ol
Numerically controlled tool rotation is possible for all tool sizes and types
and for all sheet thicknesses.
A multi-stage gear transfers the force to the upper or lower tool adapter
(C-axis), as necessary .
Tool Adapter
- ....................... 2,
Fig. 2635
"
4
B119E4 ;t-· Description 4-11
s
□ The tool adapter is referred to as a continuously rotating C-axis, as it
can rotate beyond 360°
□ It can rotate in both clockwise and counter-clockwise directions.
□ The C axis always takes the shortest path to rotate to the desired
position.
3. Tools
3.1 Criteria for tool selection
Machine type □ Permissible sheet thickness
□ Punching force
□ Tool system
□ Maximum capacity tables
Workpiece □ Sheet thickness

□ Tensile strength
Procedure □ Punching
□ Nibbling
□ Separating with slitting tools
□ Working with special tools: e. g. punching and pushing out, punch
with guided cutting edge, forming, tapping, Multitool.

3.2 Description of the tool system
A complete tool system consists of the following components:
@ = +
Punch with adjusting Punc Adjustingri

ring h ng
e
,
Stripper
Cartrid
ge
Di
e
Tool system
• Intermediate
ring
+
@
Die base
Fig. 3824
The tool set, held in a tool cartridge, is loaded into the tool adapter with
the help of this cartridge. In the process, the die plate detaches from the
cartridge.
The handle facilitates cartridge removal from the tool adapter.

The punch with adjusting ring can be easily aligned to the stripper by
using a setting aid (especially recommended for Multitools).
Setting aid Fig. 5515
Size groups The tools are available in 3 group sizes designated 0, I II.
Tools of one size group do not differ in design or in the clamping range
but only in the nominal range of their cutting geometry.
Punch The clamping diameter is identical for all sizes.
Alignment ring The adapter diameter is identical for all sizes. The alignment ring is
available in 3 different types.
Stripper The adapter diameter is identical for all sizes
Die Dies are available in 2 different sizes (I and 11). The sizes can be
compensated by an intermediate ring.
Cartridge There is only one cartridge for all three sizes and only one size of die
plate, as the dies of the size I are integrated in the intermediate ring.

3.3 Criteria for punch selection
Design
--- punch
punc
chuck
Cutting face
h
Fig. 4029 Fig. 2270
solid multi-part
L h [mm] or statement
of angle
J
Fig. 2271
straight bevelled
"Whisper Tool"
Advantages of □ Less punching force required for punches of the same size
Whisper Tools □ Lower noise levels
□ Especially effective for working tough, high-tensile materials
Punch length Punches with plane cutter surface
r:!:
Punches with sloped cutter surface
Punch length Fig. 7034
Materials □ Heavy duty high-speed steel (HSS) for heavier loads

□ HSS "oxidized" for greatest wear
□ Titanium nitrite punches for special applications (high precision
punching in aluminium etc.)
Tool dimensions The tool dimensions are engraved on the side of the punch head, e. g. 12
for a tool 12 mm square.

3.4 Components of a tool set
3.4.1 Alignment ring
Function
The alignment ring is a clamping ring which can be rotated on the punch
and clamped in any desired position. The alignment ring serves to align
the punch in the cartridge. The key in the alignment ring centers the
punch relative to the die when the punch is inserted in the punch adapter.
3.4.2 Dies
Design h h V t- h
Fig. 2275 Fig. 2276
Standard die
Reinforced version
Height h for
Size I: 18 mm Height his identical,
Size II: 20 mm additional reinforcement hv
is9mm
Application
Standard dies of size II may be used with punching forces up to 180 kN.
Dies of size I may be subjected to loads of max. 250 kN.
Size II dies of the reinforced version must be used if:

□ the punching tonnage exceeds 180 kN or
□ the stability of the standard die is not adequate on account of the
unfavorable hole geometry (e. g. oblong hole 5 x 70 mm) even
though the punching tonnage is less than 180 kN
The maximum admissible punching tonnage for size II

reinforced dies is 250 kN.

Selecting a suitable die
I ii,- i * - !) I Choice of a suitable die is also influenced by the material thickness being
worked. Thicker sheets require a larger air gap between punch and die.
The outside diameter of the die (DMat> is derived by adding:
□ the outside diameter of punch (Dst> and
□ the product of the empirically obtained value of 0.2 and the sheet
thickness (s)
3.4.3 Strippers
The stripper can assume two functions:
Stripper function The stripper prevents the sheet from being pulled up with the upstroke of
the punch, especially in thin sheets. It strips the sheet from the punch.
In this function, the stripper assumes a position about 0.5 mm

above the sheet surface during machining.
Presser foot function The stripper comes to rest on the sheet with the punch stroke, thereby
pressing the sheet onto the die beneath it. This improves the positional
accuracy of the holes and the cutting quality.
The stripper assumes this presser foot function during repositioning as
well.

Stripper selection
The necessary stripper size is dependent on:
□ the programmed sheet thickness
□ the outside diameter of the punch
□ the regrind length of the punch
The following criteria are applicable for the stripper when using specially
shaped punches:
□ For special punches with an outside diameter < 10.5 mm, choose a
stripper from the line "Punch 10.51-30.0".
□ For special punches with an outside diameter > 10.5 mm, choose a
stripper in accordance with the outside diameter of the punch.
Damage to the stripper adapter may result if the stripper

dimensions listed below are not observed!
Regrind amount O - 1.0 mm
Needle punch to 3.0 I 7I 7I 7
Needle pch. 3.01-6.0 ■ ■ ■ ■ I I I

Needle pch. 6.01-10.5 ■ ■ ■ ■ 12
12 I 1
2
I12I12
Punch 1.0-5.99 ■ 14 14 14
■ 14
14
Punch 6.0-10.5 ■ ■ ■ 14 14 14 14
■
Punch 10.51-30.0 ■ ■ ■ ■ ■ ■ ■ ■ 31
Punch 30.01-40.0 ■ ■ ■ ■ ■ ■ ■ 41 41
Punch 40.01-50.8 ■ ■ ■ ■ ■ ■
■ I52 I52
Punch 50.81-60.0 ■ ■ ■ ■ ■ ■ ■
■ ■
Punch 60.01-72.0 ■ ■ ■ ■ ■ ■ ■ ■
■
Punch 72.01-76.2 ■ ■ ■ ■ ■ ■ ■ ■
■
■ Stripper dimension corresponding to punch shape (+ 1.0 mm clearance)

Invalid sheet thickness

Regrind amount 1.1 - 2.0 mm
Needle punch to 3.0 I 7 I 7 I 7
Needle pch. 3.01-6.0 ■ ■ ■ 7

I I
Needle pch. 6.01-10.5 ■ ■ ■ 1
2
1
2
1
2
I 12 1
2
I 1
2
I
Punch 1.0-5.99 ■ 1 1
4 4 1 1 1
Punch 6.0-10.5 4 4 4
■
■ ■ 1 1 1
Punch 10.51-30.0 1 1 1 4 4 4
■ 4 4 4
■ ■
3 3 3
■ ■ ■ 1 1 1
Punch 30.01-40.0 ■ ■ ■ ■ ■ 41 4 4 4
1 1 1
Punch 40.01-50.8 ■ ■ ■ ■ ■ I 52 I 5 I 5 I 5
2 2 2
Punch 50.81-60.0 ■ ■ ■ ■ ■ ■ ■ ■ ■
Punch 60.01-72.0 ■ ■ ■ ■ ■ ■ ■ ■ ■
Punch 72.01-76.2 ■ ■ ■ ■ ■ ■ ■ ■ ■


Needle punch to 3.0 I 7 I 7 I 7
Needle pch. 3.01-6.0 ■ ■ 7 7

I I I
Needle pch. 6.01-10.5 ■ ■ 1 1 1 1 I 1 1 I 12
2 2 2 2 2 2
Punch 1.0-5.99 14 14 1 1 1 1
4 4 4 4
Punch 6.0-10.5 ■ ■ 1 1 1 1 1 1 14
4 4 4 4 4 4
Punch 10.51-30.0 ■ ■ ■ ■ ■ 3 3 3 31
1 1 1
Punch 30.01-40.0 ■ ■ ■ ■ 4 4 4 4 41
1 1 1 1
Punch 40.01-50.8 ■ ■ ■ ■ I 5 I 5 I 5 I 5 I 5
2 2 2 2 2
Punch 50.81-60.0 ■ ■ ■ ■ ■ ■ ■ ■ ■
Punch 60.01-72.0 ■ ■ ■ ■ ■ ■ ■ ■ ■
Punch 72.01-76.2 ■ ■ ■ ■ ■ ■ ■ ■ ■


5. Retractable Clamps (Option)
Machining without
On the TRUMATIC 500 ROTATION with 6 retractable clamps, the entire
remainders strips
sheet can be machined without any remainder strips (dead area).
1 2 3
Clamp in home position 3 Clamp in retracted state

2 Dead area cam
Retractable clamps Fig. 9542
5.1 Technical Data
I ilt,i tit>1i i1i,ii <>tj t iii iii <

Number of clamps 6
Number of tool stations:

TC 500R-1300 15
TC 500R-1600 17
Max. sheet thickness 8mm

I 1=tltri;tit>1i <:l F>ij §tj t i19!)9Fl <
Max. workpiece
weight: TC 500R-1300 150
TC 500R-1600 kg
230
kg
Max. stroke rate (E=1,

s=1): TC 500R-1300 650 min1-
TC 500R-1600 550 min- 1
Speed reduction area Y <97mm
Max. speed in reduction area 15 m/min
Gripping power of clamps 9000 N each
Clamp opening width 10.5 mm
Min. sheet format for machining without dead area X=800 mm

(held by 3 clamps)*
Minimum sheet format X=400 mm

(held by 2 clamps)*
Min. sheet format for machining without dead area X = 1000 mm

with TRUMALIFT SheetMaster (held by 3 clamps)
Minimum sheet format X=600 mm

with TRUMALIFT SheetMaster (held by 2 clamps)
5.2 Function
The function of the retractable clamps is illustrated below; 3 machine
states are distinguished:
3 machine states □ While machining

□ During tool change
□ While loading and unloading
• A dead strip 77 mm wide results in sheets 400 < X < 800 mm (clamps closed, dead area cam not active).

5.2.1 While machining
Sequence of 0 A clamp holding the workpiece brushes against the dead area cam,
functions the clamp opens
@ The clamp retracts
@) The clamp by-passes the punching head along the dead area cam
0 The clamp now closes. The next cycle can begin, i.e. the next clamp is
opened
: [:
0
f)
0 E)
e
2
3
Tr lam
a n p,
C
sv r e
er tra
se c
ra tab
il C le
la po
m rti
p, o
fix n
ed
po
rti
no
4
5
De nch
ad ing
Pu
ar
ea ead
ca
m
h
Sequence of functions Fig. 9471

5.2.2 During tool change
Lowering the dead
To effect a tool change, the transverse rail, carrying the new tool, travels
area cam
forward (-Y direction). The dead area cam is then lowered, so that the
tools can be changed. This up-and-down travel of the dead area cam is
monitored by proximity switches and separate overload protection.
Min. working position: Y = -7 mm Tool change position: Y = -161.5 mm
1 2
+
Y! 3
1 5
3+-t-e
-Y
t-; '+-V ...

-1 ...
I
4 c.. lLlJ 4
o.
.
Transverse rail 4 Punching station

2 Dead area cam UP Clamp 5 Dead area cam DOWN
3
Tool change Fig. 9472

5.2.3 While loading and
unloading Manual loading and
unloading
Opening the clamps For workpiece loading and unloading, each clamp is opened by
pneumatic actuation of the roller tappet valve.
□ For loading, all clamps open simultaneously or in pairs

□ For unloading, all clamps can be opened simultaneously, or clamps
1, 2 or 3, 4 or 5, 6 can be opened in pairs.
Opening in pairs Opening clamps in pairs allows the sheet to be machined a section at a
time. A finished sheet section can then be cut out and unloaded while the
remaining clamps continue to hold the rest of the sheet. Machining of the
remainder sheet can then be resumed without losing the exact position.
Sectional multi-part machining Fig. 9497

Examples of loading positions:
□ cr-. <X> l'- -<J U7 -, "'"' "- "'U7 "' fTl N 1

1N fTl N l o
N - - - - - - -
TC 500R-1300 --
mw
I rn N -
TC 500R-1300 and Stanzmitt

e
TC 500R-1600
TC 500R-1600
Loading positions (recommendations) Fig. 9512
In contrast to the other formats, the above loading position with clamps 2,
3 and 4 is recommended for sheets 1000 mm long (TC S00R-1300 and
TC S00R-1600).
Pushout of parts
Unlike standard clamps, the positions of the retractable clamps do not
have to be factored in when programming parts to be pushed out.

5.2.4 Loading/Unloading with
TRUMALIFT SheetMaster 1300/1600
If a TRUMALIFT SheetMaster is installed, clamps 1, 2 and 5 are fitted
with sensors. The sensor zero stop serves as the locator in X axis. The
clamps close if at least 2 sensors signal contact with the sheet.
The TRUMALIFT SheetMaster always aligns the sheets - regardless of

size - flush right (see diagrams below). The resulting scrap skeleton can
then be retrieved by the TRUMAGRIP 500 grippers.
Loading positions:
TC 500R-1300
N m
TC 500R-1600
Stanzmitte
Loading positions with TRUMALIFT SheetMaster Fig. 9511

6. Machining with scratch minimization
Cause of scratching
During machining, scratches can result on the surface and underside of
the workpiece when machine components rub against the material. A
critical point here is the die: Microscopic burrs, a potential source of
scratches, can form on the surface of the die.
Measures Various standard measures have already been implemented on the TC
500R to reduce scratching:
Standard □ Installation of brush panels in the area of the die adapter.
□ All support surfaces are fitted with rollers on which the workpiece
travels, with virtually no scratching, when positioning.
Option □ As an option, half the rollers can be replaced with brushes, which
further minimize scratching.
□ A pressure reducing valve can be used to decrease the pressure
exerted by the presser foot when the latter is active. This eliminates
any impressions that may otherwise result on the work surface.
2 3 1
Ball rollers 3 Die
2 Brush panels
Principle Fig. 9757

Principle
The brush panels in the area of the die adapter are 1 mm higher than the
surface of the die. When the transverse rail moves, the workpiece glides
over the brushes and does not graze the die.
E
..
E
..
Dies with brush
inserts
2 3 4
3 Workpie
2 4 ce Brush
panel
Punching head
Die
Br
u
sh
es
Clearance: Workpiece - Die Fig. 9792
To reduce scratching even further, dies with additional brush inserts are
also available.
Die with brush insert

The brushes also project about 1 mm above the die surface and bolster
the scratch reduction effect described above. Moreover, the die has a
finely polished surface. Different versions of dies and intermediate rings
with brush inserts are available from TRUMPF.
What the user can do

Besides the measures implemented on the machine, the user can also
take steps to reduce scratching:
□ Use extremely even sheets (Euronorm)
□ Clean the following daily: Table surfaces, brushes, brush panels
(especially after working sheets with scales) and support points on
the machine, as well as strippers, intermediate rings and dies
□ Whenever necessary, replace or adjust brushes and brush panels
□ Avoid upward arching of the sheet during machining (see Technical
Information: Evenness of Sheets)
□ For tool size I, use intermediate rings that are either polished or fitted
with brushes (available from TRUMPF)
□ Provide for ample tool lubrication
□ Grind off 0.03-0.05 mm from dies of size I or subtract this amount
from the shims in the intermediate ring, so that the die is seated lower
in the intermediate ring
□ Polish the top of the dies or intermediate rings and underside of
strippers (min. grain size P360)
□ Keep tools sharp at all times
□ If necessary, brush oil on the underside of the sheet
□ Position the stripper about 1 mm higher with function M282
□ Use the multiset to establish correct alignment between punch and
die (to prevent burring)

7. Sensor stop pin
The machine is equipped with a sensor stop if a TRUMALIFT
SheetMaster 1300 / 1600 for automated loading and unloading is
installed.
During manual loading on standard machines, the sheet is aligned

against the stop pin. If a SheetMaster is present, this stop pin is replaced
by a swivel sensor zero stop attached to the punching head. When a
sheet is loaded, either manually or via SheetMaster, this stop swings
downward.
Sensor clamps In addition to this, 2 or 3 clamps are fitted with sensors which must
respond together with the sensor zero stop before the clamps will close.
The sensor stop subsequently swings back into its UP position (see
"Workpiece Clamping").

8. Reference Guides
Reference guides providing further information on the different tool types

and machining processes may be ordered from TRUMPF:
Technical Information 1. Punching tools

Machining processes, terminology, feedrates, tool selection, tool
system, special tools.
2. Multitool
Multitool as a production factor, tool technology, programming
3. Softpunch
Introduction, tables, examples
4. Forming
Technology, technological variables, programming, examples and
solutions to problems
5. Special tools, forming, embossing, punching - examples
6. Tapping
Introduction, tool design, programming, technology, maintenance
7. Slotting
Slotting on TRUMPF machines, programming
8. Multi-Cut and banana tools

Tool description, Multi-Cut and banana tools as production factor, tool
technology, programming
9. Engraving
Introduction, technology, programming
10. Fastening technology- Screws in
Sheetmetal 11.Flatness of sheets

Causes of deformation, strategies for reducing deformation
12.Micro-Joint

Chapter 5
Operation
Operation
B119E5 Operation 5-1

Part 1: Operating Elements
1. Description of operating elements
The machine is equipped with operating elements located
□ away from the operator's panel

□ on the operator's panel itself:
□ Control manufacturer's panel
□ TRUMPF CNC control
A detailed description of the control panel is provided in the

manufacturer's documentation enclosed with this manual.
The operating elements are classified as follows:
□ Indicator lamp:
The lamp may be on, blinking or off. Shows the current operating
status of the machine.
□ Pushbutton:
Automatically resets to OFF when released. Luminous pushbuttons
are alight while in the ON setting and automatically reset to OFF
when released.
□ Impact switch:
Triggers EMERGENCY STOP when activated.
Turn this button to disengage it after EMERGENCY STOP.
□ Foot switch:
The operator activates this switch with his foot.
□ Switch:
Can be turned ON or OFF; remains in the activated ON or OFF
setting.
□ Potentiometer:
For infinitely variable adjustment of XN axes traverse speeds.
5-2 Operation B119E5

1.1 Operating elements away from
the operator•s panel
1
Main switch 4 Foot switch ACKNOWLEDGE LIGHT

2 Foot switch Workpiece clamping Foot
5 BARRIER
3 switch START Impact switch: EMERGENCY
STOP
Operating elements Fig. 2851
MAIN None Switch:

SWITCH
The power supply to the machine and

MAIN SWITCH
control system is turned ON or OFF
with this switch.
«l1r Main mode MACHINE -

softkey JOG MODE or
programmed stop MOO
Foot switch:
The foot switch opens or closes the

WORKPIECE in main mode NC workpiece clamps.
CL.AMPING

None Combination foot and impact switch
(Option):
The right foot switch activates the light

barrier while the left one triggers
ACKNOWLEDGE LIGHT
START. The impact switch triggers
BARRIER; START, E-STOP
EMERGENCY STOP.
If manual jog mode is active, positioning in X and Y is possible

with the clamps open and with a sheet loaded on the machine.
1.2 Operating elements at the

operator•s panel
1.2.1 Control system (TRUMAGRAPH CC220
S) operating elements
□□
13
13
I 1
Ilu =>
2
O1 3
l4
D1 3
'1J
1-6 Main modes 10 Delete key

[2 -.
7
30
!
I 71 G!1r96]E1]
7 Cursor keys and Zoom 11 Input

D131
J5
(ENTER)
IL s
O2
1
{! a9 5E1E :]
8 Numeric keypad 12 Level Return

..1
key
1
41[I 0 [
9 Arithmetic keys 13 Softkeys

1 011
1
Operator's panel Fig. 4506
Please consult the attached documentation provided by the control

system manufacturer for a detailed description of the operating elements
and control system operation.

1.2.2 Overview of main operating modes
lrnol
MANUAL
□
□
□
Input and processing of NC block information
Multiple insertion
Subroutine parameters
□ NC program run
DATA INPUT □ Program test with/without axes motion
g
□ Block run
NC □ NC program execution
□ Table activation
□ Re-approach contour
□ Program test
□ Graphic simulation
DATA 1/0 □ Editing of NC part programs

□ Input and output of parts and dialogue programs
□ Program editing
□ Copying and renaming programs
□ Protecting, deleting and managing programs
□ Graphic programming directly at the control
MACHINE □ Axes referencing

□ Axes jog mode
□ Machine functions
ILi □
□
□
Input and output of tool compensation, zero offset and laser
technology tables
Data editing
Copying and renaming tables
w
CORREC-TION
□ Protecting and erasing tables
□ Display of NC basic information

□ Error and status displays
□ Machine status and interface display
DIAGNOSTIC
□ Execution of cancel functions
□ Activation of diagnostic programs
□ Machine parameter program

1.2.3 Operating elements of the TRUMPF
CNC control
TC SOOR without autom -

@;- " -. a ti
\
o n
:
FEEDRATE
POTENTIOMETER
.
components r"\..Fv'u
/
,
START
MACHINE
r
FEED HOLD
ACKNOWLEDGE LIGHT
BARRIER
n
HIGH STROKE RATE
l@
[I]
EMERGENCY STOP
TRUMPF CNC Control without automation components Fig. 11395

TC S00R with automation components
On machines equipped with automation components, the necessary
operating buttons for such components are integrated in the control
panel.
Additional operating elements
[I Grl
(max.)
1 4 5
] ] 2 3
1 '· I·I ..L. 1 t 1,11 I·I + ILi

., I I , '· LI 10
1 6
1
I
7
. 8
8 B
11 12 13 14 15
[%! [% 18 20
] ±]
16 17 19
G 6 I;:I I;:I
TRUMPF CNC Control with automation components Fig. 11393

TRUMALIFT SheetMaster diagnostics
Extra buttons are offered on the control panel for TRUMALIFT
SheetMaster troubleshooting.
0 0
m
1
3
ffi
0 0
2
Activate Diagnostics BCD 3 Text
2 display Adopt diagnosis
Diagnostics Fig. 11392
5.8 Operation B119E5

Explanation of the operating elements
(i) none
EMERGENCY
Impact switch:
STOP
All machine motions are suspended
with this switch.
The reference points are lost.
Any program that was being

processed must be restarted.
In the event of emergencies and

machine faults which cannot be
corrected or eliminated from the
operator's panel, be very sure to
press this EMERGENCY STOP
button before undertaking any work
on the machine.
0
FEEDRATE
none
Potentiometer:
The feedrate of all axes can be

POTENTIO regulated between O and 100 % with
METER
the potentiometer. The following, for
example, applies to the X and Y axes:
between O and 108 m/min (simul
taneously in main mode NC.
[rnJ] Pushbutton:
This pushbutton inhibits all machine

none motion.
FEED HOLD The reference points remain in the

memory.

MACHINE
The control is ready. No Pushbutton:

EMERGENCY STOP in effect.
Axes limit switches not tripped This pushbutton is used to power up
or shut down the machine.
With MACHINE ON, the hydraulic
motor is activated and voltage
supplied to the ram control.
MACHINE ON is cancelled by:

□ pressing EMERGENCY STOP
□ certain malfunctions
This pushbutton blinks during

MACHINE OFF
m START
none
Pushbutton:
This pushbutton initiates main modes

NC or MDI, resets (clears) FEED
HOLD and acknowledges elimination
of certain malfunctions
[ij
ACKNOW-
none Pushbutton:
This pushbutton activates the light
barrier
LEDGE LIGHT
BARRIER
none Pushbutton:
This button is used to reduce the

stroke rate.
HIGH STROKE □ Only when using flat tools
RATE
□ Max. sheet thickness: 2.5 mm

2. Workplaces at the machine
LI]
®
1-3Workplaces
Fig. 8741
Fig. 8741 shows the workplaces the operator can work at. All workplaces
are safeguarded either by the active light barrier or by active FEED
HOLD.
For loading X
For manual removal X
2 For tooling X
3 For operation X

Part 2: Examples of operation
Safety practices
The operator should immediately press the FEED HOLD button if a

malfunction occurs while the machine is running.
If the fault cannot be rectified from the operator's panel, press impact
switch EMERGENCY STOP before any intervention at the machine itself.
Only then is the service personnel sufficiently safeguarded.
If maintenance or service is required, and not just the simple elimination

of temporary faults, be sure to turn off the main power switch to shut the
machine down.
If home position is approached when working with formed sheets (sheet

type 1), an adequate overtravel height must be assured if collisions are to
be avoided.
Due to the tool change sequence in sheet type 1, no formings may be

present within an area of 96 mm from the stop edges of the clamps.
&
The safety guidelines provided in the Operator's Manual
must be strictly observed!
Only trained personnel may be entrusted with the operation of

the machine!

1. Machine start-up and shutdown
1.1 Starting the machine up at the

beginning of the workday
AIR SUPPLY
Turn the air supply on
MAIN SWITCH
Turn the main switch on (wait until the screen display cycle ends)
(I) Disengage impact switch EMERGENCY STOP
[£] Pushbutton FEED HOLD lights up
Wait until pushbutton MACHINE blinks
w RESET
FUNCTION
Activate main mode DIAGNOSTIC
Press softkey RESET FUNCTION
CONTROL
RESET Press softkey CONTROL RESET
(the control assumes its default setting)
Press pushbutton MACHINE for at least 2 s
[ij Press pushbutton LIGHT BARRIER

With the help of the mirror on the light barrier post, assure
yourself that all persons are clear of the area safeguarded
by the light barrier
m Press pushbutton START, message "Home position missing"
Activate main mode MACHINE
MACHINE
OPERATION
Press softkey MACHINE OPERATION
REFERENC
EMACHINE
Press softkey REFERENCE MACHINE
Wait until screen display sequence ends
Display "Approaching home position"
[£] Pushbutton FEED HOLD extinguishes
1.2 Machine shutdown during

malfunctions/in
emergencies
(I) Engage the EMERGENCY STOP button

(All machine motions are suspended)

1.3 Machine shutdown at the end of
the workday
Task Transfer the tool currently in the punching adapter to the tool magazine
and switch the machine off.
Condition No program is running.
MACHINE
OPERATION
Press softkey MACHINE OPERATION
REFERENC E
MACHINE
Press softkey REFERENCE MACHINE
lrnol Activate main mode MDI
D
0
000
[ :::n:
Press softkey M
Enter "106"
G Press ENTER
D Press softkey []
G Press ENTER

0[ :::n:
Enter "O"
000
(Remove the tool)
G Press ENTER
m Press pushbutton START

(Machine assumes its home position)
Press softkey JOG MODE
[I]
I!::! El Using the cursor, center the X axis and move the Y axis towards the rear
[I] until the table segments are free of load.
Press pushbutton MACHINE
Turn the main switch OFF

MAIN
SWITCH
Turn off the air supply

AIR
SUPPLY

2. Program execution
2.1 Running a program in automatic mode
2.1.1 The tools have been loaded

Conditions □ Machine is in home position.
□ The program has already been read in.
g Activate main mode NC
PROGRAM
SELECT Press softkey PROGRAM SELECT
0[ :::n:
Enter the number of the program you want to run
000
G Press ENTER
[ij Press pushbutton ACKNOWLEDGE LIGHT BARRIER
m Press START (clamp check)
m Press START (approach loading position)

Display: "Block sequence"
Clamps open automatically

Load the workpiece
lr Press foot switch WORKPIECE CLAMPING

m Press START
2.1.2. No tools have been loaded

Conditions □ Machine is in home position
□ The program has been read in
□ Multitools must already be listed in the tool table.
PROGRAM
0 [
Enter the number of the program you want to run
:::n:
000
G
Press ENTER
Display "Load tool in magazine"
[:]
Press softkey ALL
Definition of proposed tool:
Prompt "Regrind length": for example, key in "2"; proceed likewise for the
000 other tools
000
G
Press ENTER
POSITION
RIGHT Press softkey POSITION RIGHT

m Press START
Load the tools into the magazine
ALL
FINISHED
Press softkey ALL FINISHED
m Press START (approach loading position)

Display "Block sequence"
Clamps open automatically

Load the workpiece
lr Press foot switch WORKPIECE CLAMPING
m Press START

2.2 Running a Program with Softpunch
If Softpunch was programmed in the NC text, the program can be run
with or without Softpunch.
Softkey Softpunch at the user interface of the TRUMAGRAPH control

must be activated before the Softpunch command can be executed.
Softpunch OFF is the default setting at the control.
Softpunch can be activated and cancelled while a program is running.
Activate MACHINE mode
MACHINE
OPERATION Press softkey MACHINE OPERATION
INTERVEN
TION WITH Press softkey INTERVENTION WITH AUTO
AUTO
SOFTPUNC
HON Press softkey SOFTPUNCH ON

2.3 Executing a single stroke
A single stroke is used to:
□ cut a part free or to cut off a scrap skeleton
□ examine farmings
Conditions □ A tool must be present in the adapter.

□ The tool must be loaded with M81/M106 if forming was done earlier.
lul Activate main mode MDI

Specify the sheet thickness via M28S. as follows:
D
0 [ :::n:
Press softkey M
Key in "28"
000
G Press ENTER
D
000
Press softkey S
Enter the sheet thickness (e.g. 1.5)

000
G Press ENTER

(Working height is approached)

MACHINE
OPERATIO
N Press softkey MACHINE OPERATION
MANUAL
INTER
VENTION Press softkey MANUAL INTERVENTION
SINGLE
STROKE
Press softkey SINGLE STROKE
A single stroke is executed
2.4 Program stop while machining
You can stop the machine if you want to check the work in progress.
Condition: A program is running.
[£] Press pushbutton FEED HOLD

All machine motion is halted
(Punching results can be checked)
[£] Pushbutton FEED HOLD is no longer illuminated
m Press the START button

The machine resumes operation

2.5 To interrupt a program
Condition A program is running.
either:
PROGRAM
SELECT
Press softkey PROGRAM SELECT
LEAVE Press softkey LEAVE PROGRAM

PROGRAM
or:
[I] Activate main mode DIAGNOSTIC
Press Softkey RESET FUNCTION

RESET
FUNCTION
Press Softkey CONTROL RESET

CONTROL
RESET
The program is interrupted.

3. Resuming a NC program after
an interruption
3.1 Resuming via 11Search Block 11

To resume a TC-CAPT or ToPs 200 program (for example after an
EMERGENCY STOP), proceed as described below:
Conditions □ The required tool must be present in the tool adapter.

(I) Disengage the EMERGENCY STOP button
w Activate main mode DIAGNOSTIC

RE
SE
T

FU
NC
TI
ON
Press softkey CONTROL RESET

CO
N
TR
O LR
ES
ET
MACHINE

REFERENC
lrnol
E Press softkey REFERENCE MACHINE
MACHINE
Select MANUAL DATA INPUT mode
Key in the sheet thickness via M28S:
D
0
000
[ :::n: Press softkey M
G
Enter "28"
D
Press ENTER
000 Press softkey S

000
G Key in the sheet thickness (e.g. 1.5)
m Press ENTER
g Press START
Select main mode NC
You wish, for instance, to resume program 12:

Press softkey PROGRAM SELECT
PROGRA
000M SELECT
Enter the program number, e.g. "12"
000

G Press ENTER
m
Message "Clamp check NC start" appears
Press pushbutton START twice (for clamp check and to assume sheet
loading position)
SEARCH BLOCK
Press softkey SEARCH BLOCK
One position after the last tool change must be selected.

0[ :::n:
e.g. key in "21O"
000
G Press ENTER
Machine resumes operation with program No. 12

Go Block
3.2 Resuming via 11Go Block 11

After program interruption (for example, after an EMERGENCY STOP),
resume the program as described below:
Conditions □ The required tool must be in the tool adapter.

Disengage the EMERGENCY STOP button
w
RESET FUNCTION

CONTROL RESET
MACHINE
REFERENC
E Press softkey REFERENCE MACHINE
MACHINE

PROGRAM
0[ :::n: You wish, for instance, to continue running program No. 12

Key in the program number, e.g. "12"
000
G Press ENTER
m
Display "Clamp check Start NC" appears
Press pushbutton START twice
Press softkey GO BLOCK

Display: "DO YOU WANT TO SEARCH MAIN BLOCK?"
[I]
I!::! El Use the cursor to find the block number of the last tool change
[I]
[:] Press softkey NO

000
Enter the block number where the program will be resumed
000
One position after the last tool change must be selected.
G Press ENTER
Display: "GO BLOCK LEVEL 1"

000
Enter, e.g. "150"
000

G Press ENTER
m Wait until message "Start approach" is displayed. Press pushbutton

START
The program is resumed
3.3 Resuming a program via 11Simulation11
3.3.1 When using a punching tool

After a program interruption (for example, after an EMERGENCY STOP),
Conditions □ The required tool must be in the tool adapter.
(I) Disengage the EMERGENCY STOP button
RESET
FUNCTION

CONTROL
RESET
MACHINE
REFERENC
g
E
MACHINE Press softkey REFERENCE MACHINE
Activate main mode NC
SIMULATION
Press softkey SIMULATION
You wish, for instance, to continue with program No. 12:

0[ :::n:
Type in the program number "12"
000
G Press ENTER
m Press pushbutton START (clamp check)
B Press softkey PRERUN
A graphic simulation of the program is displayed.
You can use softkey STOP to halt the program.
Softkey STEP allows you to advance the program stroke by stroke
STOP
STEP

The program is resumed.
This method of resuming a program after an interruption cannot

be used:
□after repositioning
□if using a tapping tool
3.3.2 When using a tapping tool

After a program interruption (for example, after an EMERGENCY STOP),
Condition
The tapping tool, in its adjusted state, must currently be located in the
tool magazine, and not in the tool adapter!
lrnol Select main mode MANUAL DATA INPUT
D
0 [ :::n:
Press softkey M
Key in "28"
000
G Press ENTER
D Press softkey S

0[ :::n:
Key in, e.g. "2" (sheet thickness)
000
G Press ENTER
m Press START
D000
Press softkey M
Key in "816"
000
G Press ENTER
D Press softkey []
G Press ENTER
Enter the parameters:

000
000 e.g. P1: [3.9, ,, o, 0.5, 1]
G Press ENTER
Press softkey INSERT PARAMETERS - comma is generated
INSERT
PARA
Then insert parameters as described above
METERS

m Then press START
D
0[ :::n:
Press softkey M
Key in "106"
000
G Press ENTER
D Press softkey []
G
000
Press ENTER
Enter the magazine station number - e.g. "3"

000
G Press ENTER
m Press START
Load the tapping tool into the tool adapter
□ SIMU
LATION
Activate NC mode
Press softkey SIMULATION
You wish, e.g. to resume program No. 12:

000
Key in program number "12"
000
G Press ENTER

B Press softkey PRERUN
A graphic simulation of the program is displayed.
STOP You can use softkey STOP to halt the program.

STEP
Softkey STEP allows you to advance the program from one thread to the
next.
m Press START
The program is resumed.

4. Service and diagnostic functions
4.1 Securing the axes against

unauthorized intervention
B Press softkey STATUS
L j Press softkey TEST ON
ALL AXES
INHIBIT
Press softkey ALL AXES INHIBIT or AXIS INHIBIT

AXIS INHIBIT To release the axes, simply press the same softkey again.
You can also use softkey TEST OFF to release the axes.
4.2 Machine status display (MSD)
[:]
Press softkey DIAGNOSTIC MACHINE
DIAGNOS
TIC
MACHINE
Press softkey MSD

L:_J Press softkey NEXT PAGE
The highlighted items in the display indicate the operating status of the
machine.
4.3 Displaying inputs and outputs
w DIAGNOS
TIC
MACHINE
Press softkey DIAGNOSTIC MACHINE
1/OSTATU
S
INDICATO Press softkey 1/0 STATUS INDICATOR
R
Press softkey IOS-PLC IOS-PLC
Press softkey INPUTS or OUTPUTS as desired

INPUTS
H =High= on
L =Low= off
OUTPUTS
G
For example, you want to check input E42:
Press softkey INPUTS
0[ :::n: Key in "42"

000

G Press
ENTER
Example:
0 1 2 3 4 5 6 7 (bits)
E42 L H H L L L H H (status)
(Display in the screen center)
4.4 Checking the software version
w
DIAGNOS
TIC
CONTROL
Press softkey DIAGNOSTIC CONTROL
Press softkey SOFTWARE VERSION

SOFTWAR
E
VERSION
The software version in the control is displayed.
4.5 Activating the screen saver

To prevent the image from "burning in", the screen saver can be
activated after an allotted time.

DIAGNOS
TIC
CONTROL Press Softkey DIAGNOSTIC CONTROL
OTHER
FUNCTION
S Press softkey OTHER FUNCTIONS twice
SCREEN
[:]
DARKEN
Press softkey SCREEN DARKEN
D
Press softkey OFF - "Screen darken not active" is inverted
Press e.g. softkey 5 (or 15, 30, 60) minutes
The screen darkens when the programmed time expires. Press any key
to re-activate the screen.
4.6 Cursor bar for faster operation

Such procedures as program management can be sped up by using the
cursor bar, which marks a whole line.
Press Softkey DIAGNOSTIC CONTROL

DIAGNOSTIC
CONTROL
Press softkey OTHER FUNCTIONS twice
OTHER FUNCTIONS
Press softkey FILE SELECTION

The cursor bar is displayed.
FILE SELECTION

4.7 Setting the date and time
w DIAGNOS
TIC
CONTROL
Press softkey DIAGNOSTIC CONTROL
OTHER
FUNCTIO
NS Press softkey OTHER FUNCTIONS twice
ADJUST
CLOCK
Press softkey ADJUST CLOCK
B Set the date and time via softkeys MINUTE, HOUR, MONTH, DAY
4.8 Sorting files

With this function, files (programs) can be listed in ascending order or
according to type.
w
DIAGNOS
TIC
Press Softkey DIAGNOSTIC CONTROL

CONTROL
OTHER
FUNCTIONS Press softkey OTHER FUNCTIONS twice
SORT
FILES Press softkey SORT FILES.

5. Solutions to problems:
Example 1:
The tool table still lists one tool although all tools have been removed
from the tool magazine. The missing tool must be loaded.
Since there are no tools in the magazine, the latter comes to a stop in
front of the tool adapter.
Message "Wrong magazine station".

This message is also displayed if tools are not loaded properly (not
snapped in position).
Condition Main mode NC is active.
Load the missing tool
I CONmNUE I Press softkey CONTINUE
Message "Start NC for clamp check"

(clamp check and to start the program)

Example 2: Function enable in the event of collision between tool and workpiece
(hydraulic system and drives were not shut off during the collision)
w
RESET FUNCTION
CONTROL
RESET
MACHINE
OPERATIO Press softkey MACHINE OPERATION
N
MANUAL
INTER Press softkey MANUAL INTERVENTION
VENTION
I CONmNUE I Press softkey CONTINUE
Press softkey RELEASE WORKPIECE

(Ram goes up)
RELEASE
«l1r
WORKPIE
C Press foot switch WORKPIECE CLAMPING and remove the workpiece
E
or
Press LEVEL RETURN and
Press softkey OPEN/CLOSE CLAMPS
□
OPEN/
CLOSE Do not touch the sheet when the clamps open because tension
CLAMPS may be released from the material, causing injuries. The
reference point of the ram does not remain in the memory. The
ram, therefore, must be referenced again.

Example 3:
Function enable in case of collision between punch and workpiece
(hydraulic system and drives were deactivated by the collision, e.g. in a
collision with a thick workpiece).
The machine cannot be switched on although pushbutton MACHINE is

blinking. Therefore:
If the machine cannot be switched off with pushbutton MACHINE,

proceed as follows:
(I) Press the EMERGENCY STOP button
(I) Release the EMERGENCY STOP button

RE UN
F
SE CT

T I
ON

CO ES
R
No FEED HOLD may exist

NT ET
RO
L
Press pushbutton ACKNOWLEDGE LIGHT BARRIER
[ij
Press pushbutton START
m Press foot switch WORKPIECE CLAMPING, remove the workpiece and

reference the machine again.
«l1r

6. Program Input and Output
6.1 Device connection and settings

Programs can be input and output via disk station GNT 7101/GNT 7102
or via PC-TRANSFER/TC-TRANSFER. Correct data transmission is
contingent on proper device setting and connection to the control system.
The following device settings are necessary:
Interface 20 Interface Interface 20

mAN24 V24 mA
Code ISO Interfac RS232Interface:20mACL
: e:
Baudrate:9600 Baudrate:9600 Baudrate:9600
Stop bit:2 Data 7 Data bits:7

bits:
Protocol:Mode 1 Stop 1 Stop
bits: bits:
% Check:No Parit eve Parit eve
y: n y: n
EOB-Code: CRLF Handshake:XON/XOFF Handshake: XON/OFF
TV Check: No Code ISO Code ISO

: :
Null Code: EOB-Code:CR/LF EOB-Code:CR/LF
No
Timeout ON: Timeout ON:
2 2
Timeout OFF: Timeout AUS:
2 2
Name start:FS, Name start:FS,
Prg.-start:none Prg.-start:none
Prg.-stop 1-4: Prg.-stop 1-4:

none none
Divisio yes Divisio yes
n: n:
Leader non Leader non
: e : e
V- XON V- TRALOC
char.: char.:
Traile non Traile non
r: e r: e
N- XOFF N- TRALOC
char.: char.:
Protoc non Protoc non
ol: e ol: e

Parameter setting: Parameter setting:
Press key 7 and ENT Press the PARAMETER key
Only DD disks (3 1/2") DD and HD disks (3 1/2") accepted
Interface V24.1 Interface V24.2
Socket: DTE RS 232/20 mA
Data cable ldent. Nr. 091329 Data cable ldent. Nr. 216124
6.2 Uploading NC programs

You wish to upload an NC program from a disk into the NC control using
disk station GNT 7101/GNT 7102.
Select main mode DATA 1/0
B Press softkey DATA IN
Dependent on the device you are using:
GNT 7101 GNT 7102
Message:"DATA IN V24.1/20mA Message: "DATA IN V24.2 DCR

DCR 9600 BAUD" displayed at 9600 BAUD" displayed at panel
panel

'- If no message is displayed:
DEVICE
SELECTION Press softkey DEVICE SELECTION
GNTXXXX Press softkey GNT XXXX, XXX BAUD if not yet

XXXBAUD highlighted
[:] Press softkey PORT
V24.1/
20MA
Press softkey V24.1/20MA/V24.2 if not yet

highlighted
V24.2
0 Press LEVEL RETURN twice
DEVICE Press softkey DEVICE CONTROL if not yet highlighted

CONTROL
0 Press LEVEL RETURN

The following settings are required at the data transfer device before an
NC program can be read into the NC control.
GNT 7101 GNT 7102
Press key 2 twice Press key DATA OUT

Display: "Program Use the cursor to select the
code?" desired
Enter the number of the program you
want uploaded program
Press key ENT

G Press softkey START
(Do not press any other key as long START is highlighted).
GNT 7101 GNT 7102
Press key ENT Press key ACTION

Message:"Output completed" Message:"Transfer
appears appears completed"
The NC program has been loaded into the NC control.
6.3 Uploading graphic programs

You wish to upload a graphic program from a disk into the NC control
using disk station GNT 7101/GNT 7102.
GRAPHIC
MODE Press softkey GRAPHIC MODE
READ IN
GRAPHIC Press softkey READ IN GRAPHIC
GNT 7101 GNT 7102
Message: "DATA IN V24.1/20 mA Message: "DATA IN V24.2 DCR

DCR 9600 BAUD" displayed at 9600 BAUD" displayed at panel
panel

'- If no message is displayed:
DEVICE SELECTION Press softkey DEVICE SELECTION
GNTXXXX XXXBAUD
Press softkey GNT XXXX, XXX BAUD if not yet

highlighted
Press softkey PORT PORT
V24.1/
20MA Press softkey V24.1/20MA/V24.2 if not yet
highlighted
V24.2
DEVICE
CONTROL Press softkey DEVICE CONTROL if not yet highlighted

The following settings are required at the data transfer device before a
graphic program can be read into the NC control.
GNT 7101 GNT 7102
Press key 2 twice Press key DATA OUT

Display:"Program code?" Use the cursor to select the
Enter the number of the program you desired progra
m
want uploaded
Press key ENT

(Do not press any other key as long START is highlighted).
GNT 7101 GNT 7102
Press key ENT Press key ACTION

Message:"Output completed" Message:"Transfer
appears appears completed"
The NC program has been loaded into the NC control.
6.4 Uploading NC programs via

PC/TC TRANSFER
You wish to upload an NC program into the NC control for example from
a TC-CAPT system, using the PC/TC-TRANSFER data transmission
program.
A command program P1 must be edited before an NC program can be

read in. This program P1 needs to be created only once. Create this
program as described below:
[:] Select main mode DATA 1/0
Press softkey EDIT
SCREEN
EDITOR Press softkey SCREEN EDITOR if it is not highlighted
• If no program has been edited yet:

0[ :::n:
000
G
or:
Press ENTER
'- If programs were already edited earlier (Message "Edit

further processing of last program?"):
[J
Press softkey NO
000
000
Press ENTER
G
D Press softkey N
G
000
Press ENTER
Enter "10"
000
D Press softkey Q
G Press ENTER
000
Key in the program number, e.g. "4711"
000

Command program P1 has now been generated:
P1
N10 Q4711
N20 M30
Block N20 is generated automatically when you press level return. This
command program needs to be edited only once. For subsequent
transfers, all you have to do is change the number of the requested
program. More than one program may be listed in P1.
The command program with the requested NC program is now sent from
the NC control to the computer.
Proceed as follows:
Press softkey DATA OUT
Message "DATA OUT V24.1/20MA OCR 4800 Baud"
appears '-If message "DATA OUT V24.1/20MA OCR
4800 Baud"
is not displayed:
DEVICE Press softkey DEVICE SELECTION

SELECTION
OCR Press softkey OCR 4800 BAUD if it is not

4800 BAUD highlighted
V24.1/ Press softkey V24.1/20MA if not yet highlighted.

20MA

DEVI
Press softkey DEVICE CONTROL
CE if not yet highlighted
CONTR
OL
DFS
RECOGNIZ Press softkey DFS RECOGNIZE if not yet highlighted
E
WIT
H Press softkey WITH LEADER if not yet highlighted
LEAD
ER
WIT
H Press softkey WITH TRAILER if not yet highlighted
TRAIL
ER
I DATAOUT I Press softkey DATA OUT

PA
R
Press softkey PART PROGRAM

T
PR
OG
RA
M
0[ :::n:
000
Press ENTER
G The TC-CAPT computer must be on and the port to the respective

machine must be active.
Press softkey START
G The NC control transfers command program P1 to the TC-CAPT

computer.
Press LEVEL RETURN twice
0 Press softkey DATA IN
B
The NC program is read into the NC control.
An error file, P9, is generated if the requested program does not

exist in the computer. P9 can be activated in main mode NC
and displayed as error text.
6.5 Downloading NC programs

You wish to download an NC program from the NC control via disk
station 7101n102, and store it on disk (no output list exists as yet in the
NC control).
Depending on the transmission device in use:
GNT 7101 GNT 7102
Message:"DATA OUT V24.1/20 mA Message:"DATA OUT V24.2 DCR

DCR 9600 BAUD" appears 9600 BAUD" appears
• 1t this message is not displayed:
Press softkey DEVICE SELECTION
DEVICE SELECTION

XXXBAUD highlighted
V24.1/ Press softkey V24.1/20MA/V24.2 if not yet

20MA
highlighted
V24.2
B DEVI
CE
Press softkey STATUS
if not yet highlighted

CONTR
OL
DFS-
RECOGN Press softkey DFS RECOGNIZE if not yet highlighted
IZE
WIT
LEAD
ER
WIT
TRAIL
ER
SEVERAL
FILES Press softkey SEVERAL FILES
FURTHER
ENTRIES Press softkey FURTHER ENTRIES

MAIN
AND
PARTPR Press softkey MAIN AND PART PRG.
G.
0[ :::n: Key in the program number

000
G Press ENTER
The following settings are required at the data transfer device before an
NC program can be dowloaded from the NC control.
Depending on the device you are using:
GNT 7101 GNT 7102
Press key 1 Press key DATA IN

Press key 2 Designation: AUTOMATIC
Display:"Program code?" Press key ACTION
Enter the number of the program
you want to download
Press key ENT
Depending on the device in use:
GNT 7101 GNT 7102
Press the ESC/STOP key To check: Press the LIST key

To check: Press key PROGRAM (the list must include the
LIST (the program list must include desired program)
the desired program)
The NC program is downloaded from the NC control.
All files you wish to download must be entered in an output list.

The operations sequence depends on whether such a list
already exists. If not, use softkey MAIN AND PART PRG. as
described to add a main program with its subprograms in the
newly generated list and download them.

An existing output list can be erased with softkey NEW
SELECTION, modified via softkey MODIFY SELECTION or
supplemented with other programs using softkey FURTHER
ENTRIES. After each of these procedures, press softkey MAIN
AND PART PRG.
6.6 Downloading graphic programs

You wish to download a graphic program from the NC control via disk
station 7101/7102, and store it on disk.
GRAPHIC MODE
Press softkey GRAPHIC MODE
OUTPUT GRAPHIC
Press softkey OUTPUT GRAPHIC
Depending on the transmission device you are using:
GNT 7101 GNT 7102
Message:"DATA OUT V24.1/20 mA Message:"DATA OUT V24.2 DCR

DCR 9600 BAUD" appears 9600 BAUD" appears
• If this message is not displayed:
DEVICE SELECTION

XXXBAUD highlighted
V24.1/ Press softkey V24.1/20MA/V24.2 if not yet

20MA
highlighted
V24.2
B DEVI
CE
Press softkey STATUS
if not yet highlighted

CONTR
OL
DFS-
RECOGN Press softkey DFS RECOGNIZE if not yet highlighted
IZE
WIT
LEAD
ER
WIT
TRAIL
ER
GRAPHIC
PROGRAM Press softkey GRAPHIC PROGRAM
either:
[I]
Use the cursor to select the program
I!::! El
[I]

G Press ENTER
or:
Key in the desired program number
0[ :::n:
000
G Press ENTER
The following settings are required at the data transfer device before a
graphic program can be dowloaded from the NC control.
GNT 7101 GNT 7102
Press key 1 Press key DATA IN

Press key 2 Designation: AUTOMATIC
Display:"Program code?" Press key ACTION
Enter the number of the program
you want to download
Press key ENT
GNT 7101 GNT 7102
Press the ESC/STOP key To check: Press the LIST key

To check: Press key PROGRAM (the list must include the
LIST (the program list must include desired program)
the desired program)
The graphic program is downloaded from the NC control.


AND PART PRG.
6.7 Downloading NC programs via

PC/TC TRANSFER
You wish to download an NC program from the NC control to a TC-CAPT
system using the PC/TC-TRANSFER data transmission program (no
output list exists yet).
Message "DATA OUT V24.1/20MA OCR 4800 Baud" appears.
•If message "DATA OUT V24.1/20MA OCR 4800

Baud" is not displayed:
DEVICE SELECTION
Press softkey OCR 4800 BAUD if it is not

highlighted
OCR 4800 BAUD

[:]
Press softkey PORT
V24.1/ Press softkey V24.1/20MA if not highlighted

20MA
Press softkey STATUS STATUS
DEVI
CE Press softkey DEVICE CONTROL if not yet highlighted
CONTR
OL
DFS-
RECOGNIZ Press softkey DFS RECOGNIZE if not yet highlighted
E
WIT
LEAD
ER
WIT
TRAIL
ER
SEVERAL
FILES Press softkey SEVERAL FILES
FURTHER
MAIN AND
PARTPRG. Press softkey MAIN AND PART PRG.
0[ :::n:
Key in the program number
000

G Press ENTER
The TC-CAPT computer must be on and the port to the respective

machine must be active.
TC-TRANSFER sends the NC program from the NC control to a TC

CAPT computer.


AND PART PRG.

7. Management of programs and tables
7.1 Deleting NC programs
You wish to delete an NC program from the NC control.
B Press softkey MANAGE
B
SEVERAL
FILES
Press softkey DELETE
Press softkey SEVERAL FILES
FURTHER
a) If no programs were deleted previously:

MAIN AND
b) If programs were deleted earlier:

NEW
SELECTION Press softkey NEW SELECTION
MAIN AND
0[ :::n:
Enter the number of the program you want to delete
000

G Press ENTER
G Press Softkey START

This deletes the NC program.
NEW
SELECTIO
N Press softkey NEW SELECTION
A CONTROL RESET should always be made after any changes affecting

the memory (e.g. after deleting programs) in order to update memory
mapping:
w RESET
FUNCTIO Press softkey RESET FUNCTION

N

CONTROL
RESET
Memory mapping is refreshed and the link table deleted.
7.2 Deleting graphic programs

You wish to delete a graphic program from the NC control.
Activate main mode DATA 1/0

GRAPHIC
MODE
Press softkey GRAPHIC MODE
MANAGE
B
GRAPHIC
Press softkey MANAGE GRAPHIC

PR
OG
RA
M
NU
M
BE
Press softkey PROGRAM NUMBER

R
Enter the number of the program you want to delete

0[ :::n:
000
G Press ENTER
This deletes the graphic program.
A CONTROL RESET should always be made after any changes affecting

the memory (e.g. after deleting programs) in order to update memory
w
mapping:

RESET FUNCTION
CONTROL RESET
The memory mapping is refreshed and the link table deleted.

7.3 Displaying an NC text
You wish to display the NC text of an NC program currently in the NC
control.
[:] Select main mode DATA 1/0
Press softkey EDIT

NC EDITOR
Press softkey NC EDITOR or SCREEN EDITOR

SCREEN
EDITOR
either:
• If no programs have been edited as yet:

0[ :::n:
Enter the program number
000
G
Press ENTER
The NC text of the desired program is displayed.
or:
• If programs were edited prior to this, the following message will

appear when you press softkey NC EDITOR or SCREEN EDITOR:
"Edit further processing of the previous program?"
If further processing is desired:

Press softkey YES
The NC text of the previously edited program is
displayed
If no further processing is desired:

YES
Press softkey NO
NO

0[ :::n:
After that:
000
Enter the desired program number
G
Press ENTER
The NC text of the selected program is displayed.
7.4 Editing an NC text (examples)
Note
A program may already be active in main mode NC for text display and
function search. If this is the case when you want to edit the NC text,
deactivate the program as follows.
Select main mode DIAGNOSTIC
w
RESET
FUNCTION
CONTROL Press softkey CONTROL RESET
RESET

Example 1: Search for a particular block in the program (N100)
[:] Press softkey EDIT
SCREEN
EDITOR Press softkey SCREEN EDITOR if it is not highlighted
• If no program has been edited yet:

0 [
:::n: Enter the program number
000
G
Press ENTER

appear when you press softkey SCREEN EDITOR:

Press softkey YES
displayed
YES If no further processing is desired:

NO
Press softkey NO
000
After that:
000 Enter the desired program number
G
Press ENTER
B
OTHER
COMMAN
DS Press softkey OTHER COMMANDS
Press softkey SEARCH
D
DEFINE
STRING
Press softkey DEFINE STRING
Press softkey N
G
0[ :::n:
000
Press ENTER
8
Enter "100"
Press softkey FINISHED
The cursor jumps to the defined block (N100)

Example 2:
Search for a particular function in the NC program (M06)
SCREEN
EDITOR Press softkey SCREEN EDITOR
• &i P3ffiograms ha&ltma:hmpnegr,et:number

[2]00
G
Press ENTER

appear when you press softkey SCREEN EDITOR:

Press softkey YES
displayed
YES If no further processing is desired:

NO
Press softkey NO
Then:
0 [ Enter the desired program number
:::n:
[2]00

G
Press ENTER
OTHER
B
COMMANDS
Press softkey OTHER COMMANDS
Press softkey SEARCH
DEFINE STRING
D
Press softkey DEFINE STRING
Press softkey M
G 0 [
:::n:
000
Press ENTER
Enter "06"
8 Press softkey FINISHED
The cursor jumps to the desired function
Press softkey SEARCH NEXT or softkey FORWARDS/BACKWARDS.
SEARCH NEXT
FORWARDS BACK
WARDS
The cursor jumps to the next occurrence of the previously defined search
string every time you press SEARCH NEXT.
The search takes place either from the beginning to the end of the
program, or vice-versa, depending on the activation of softkey
FORWARDS/BACKWARDS (forward/backward).
Example 3:
You wish to add a block to the NC program
(Function M58 in block N150)
SCREEN
If no programs have been edited yet:

0 [ :::n:
000
G Press ENTER
If programs were edited prior to this, the following message will appear
when you press softkey SCREEN EDITOR:

YES Press softkey YES
The NC text of the previously edited program is displayed
NO If no further processing is desired:

Press softkey NO
Then:
000
000

G Press ENTER

[I]
I!::! El Position the cursor to the line (behind the last character) which will
[I] precede the line you want to add.
OTHER
COMMAN
G Press ENTER (this creates a blank line)
□ Press LEVEL RETURN. The letters of the alphabet (e.g. M, F, G...)

appear in the softkey bar. You can now insert a block.
D Press softkey N
G
0 [ :::n:
Press ENTER
Enter "150"
000
D Press softkey M
G
000
Press ENTER
Enter "58"
000
Block N150 with function M58 is inserted in the NC program.

Example 4: You wish to delete a block, a word or a character from the NC program.
SCREEN

0 [ :::n:
000
G Press ENTER


Press softkey NO
Then:
000
000
G Press ENTER

OTHER
B
COMMAN
[I] Press softkey DELETE

I!::! El
[I]
Use the cursor to select the block, word or character you want to delete
DEL
ET
E
LIN
E Press softkey DELETE LINE, DELETE WORD or DELETE CHAR
DEL
ETE
WO
RD
DEL
ETE
CH
This deletes the line, word or character.
Any lines, words or characters that were inadvertently deleted can be

reactivated:
I R=RE I
Press softkey RESTORE
RESTO
RE
LIN
E
RESTO Press softkey RESTORE LINE, RESTORE WORD or RESTORE CHAR
RE as required to revoke the deletion.
WOR
D
RESTO
RE
CHA
R

Example 5: Automatic block numbering
Block numbers can be assigned automatically while the program is being

created or while making additions to the program.
SCREEN

0 [ :::n:
000
G Press ENTER


Press softkey NO
Then:
000
000

G Press ENTER

OTHER
COMMANDS
Press softkey OTHER COMMANDS twice
[I]
I!::! El Position the cursor to the line (behind the last character) after which
[I] automatic block numbering will start.
AUTO LINE
NUMBER
Press softkey AUTO LINE NUMBER
0[ :::n:
Specify the desired range and increments (interactive guidance):
000
e.g. from: 21O to: 31O Iner: 1O
G Press ENTER after each input
The blocks of the NC program will then be numbered consecutively:

N210
N220
N230
N310

8. Tools and tool tables
8.1 Creating tool tables and loading tools

into the linear magazine
The tool table tells the control at which magazine station the clamps and
tools are located; it also provides such information as the tool shape,
regrind length and whether it is a Whispertool or not.
You wish to create a tool table e.g. of the following type:

One tool (square 20; regrind length: 2.0) is to be loaded into the tool
magazine and two clamps (stations 2 and 10) will be set. The clamps do
not need to be set if Option "Retractable Clamps" is installed.
In forming, a "negative regrind length" can be programmed - to

compensate the deflection of the machine frame.
□ TOOL
TABLE
Activate main mode CORRECTION
Press softkey TOOL TABLE
[:] Press softkey EDIT (if tools have already been entered in the tool table)
Set the first clamp:
[:] Press softkey STATION and key in the station number, e.g. "2"
0 [
Key in the station, e.g. "2",
:::n:
000
G
Press ENTER
(Cursor jumps to station 2)

B Press softkey OTHERS twice
B Press softkey CLAMP
[I]
Set the 2nd clamp:
I!::! El
[I] Advance the cursor to station 1O
B Press softkey OTHERS twice
B Press softkey CLAMP (the same applies to option 3 or 4 clamps)
[:J Set the 1st tool:
Press softkey STATION

0 [
:::n: Key in the station number, e.g. "5"
000
G Press ENTER
a000
000
Press softkey SQUARE
Display "Edge length" - Key in "20"

G 0 [
Press ENTER
:::n: Display "Sheet thickness" - Key in "2"

000
G 000
Press ENTER
Display "Regrind length" - Key in "2.0"

The regrind length is the sum of the amount ground off the punch plus 1
000
mm depth of ram penetration into the die (to assure punching through).
See chapter DESCRIPTION.
(Determine the regrind length e. g. with MULTISET)
G Press ENTER
Display "Whisper tool?"
Press softkey YES or NO

YES
NO Proceed in the same manner for any additional tools you may wish to list
in the tool table.
(The new tool is marked with an * on the screen)
Press LEVEL RETURN twice
0
Press softkey ADOPT TABLE
ADOPT TABLE
[:] Press softkey ALL
Softkey POSITION RIGHT allows you to move the X axis to the right for
tool loading.
POSITION RIGHT

The position on the right is approached, softkey POSITION LEFT

appears in the softkey bar on the screen
Load the new tool set, letting it lock in place (station 5)
The operator can swing the control panel over to his field of vision while
he is loading the tool.
Stations 18, 19 and 20 (21 - Option) must be loaded from the left. To do
so:
ALL FINISHED
If the number of tools needed in a program exceeds the number

of available tool stations, the tool set which is listed in the table
but missing from the magazine is always requested at station 1.
If station 1 is occupied by a clamp, the missing tool will be
requested at magazine station 2.
8.2 Creating a tool table when using Multitools
Create a tool table containing a Multitool.
□ TOOL
TABLE
Activate main mode CORRECTION
Press softkey TOOL TABLE
[:] Press softkey EDIT (if tools are already listed in the table)

I TOOL TWE I Press softkey TOOL TYPE
0 [ :::n:
Display "Edit station number" - Key in e.g. "3"
000
G 000
Press softkey ENTER
Display "Edit tool type" - Key in "4" (for a 4-station Multitool, e.g. station 3
000 is divided into 3.01, 3.02, 3.03 and 3.04)
ENTER Press softkey ENTER

ROUND
Press e.g. softkey ROUND
000
Display "Round diameter" - Key in e.g. "6"
000
G Press softkey ENTER

Display "Edit sheet thickness"
Press softkey COMPLETE TOOL or THIS PUNCH
COMPLETE
TOOL
THIS PUNCH
000 Key in e.g. "2"

000
G 000
Press softkey ENTER
Display "Edit regrind length" - Key in "1.0" (only for 12-station Multitool)
000
G Press softkey ENTER

[I]
Proceed in like manner to enter additional Multitool punches in the tool
I!::! El table. Set the cursor to the next Multitool station.
[I]
8.3 Tooling the linear

magazine/Exchanging tools (examples)
Example 1: Changing tools in the magazine
Task Remove a tool from the magazine and load a new tool (20 mm square;
regrind length: 1.0).
Condition There are tools in the magazine
ILi Activate main mode CORRECTION
TOOL
TABLE Press softkey TOOL TABLE
(The tool table is displayed)
[I]
I!::! El Position the cursor to the tool you wish to remove (e.g. station 1)
[I]
G Press softkey SHAPE
a0[
000
:::n:
Press softkey SQUARE
Display "Edge length" - Key in "20"

G
SHEET THICKNESS
ENTER
Press ENTER
Press softkey SHEET THICKNESS - Key in "2"
Press ENTER
B Press softkey OTHERS
Display: "Edit data"
WHISPER
TOOL
Press softkey WHISPER TOOL
YES
NO Press softkey YES or NO
0 Press LEVEL RETURN twice and then:
REGRIND LENGTH Press softkey REGRIND LENGTH - Key in "1.0"
G Press ENTER
Proceed in like manner if additional tools are to be exchanged.
0 Press LEVEL RETURN twice and then:
ADOPT
TABLE Press softkey ADOPT TABLE
(The new tool is displayed with an *)
[:] Press softkey ALL
POSITION Using softkey POSITION RIGHT, you can move the X axis to the right for
RIGHT
tool loading (station 1)
m
ALL
To do so: Press pushbutton START
With the aid of an accessory tool for leverage, remove the current tool
from station 1 and load the new tool, letting it snap in place.
FINISHED
Example 2: Deleting one or several tools or clamps from the tool table
Task Remove a tool from the magazine

Delete this tool from the tool table (e.g. station 1)
Condition The tool you wish to remove is present in the magazine and is listed in
the tool table.
IL Activate main mode CORRECTION
iTOOL
TABLE Press softkey TOOL TABLE
B
Press softkey ALL (clamps and tools)
NUMBER (station number of clamps
ALL or tools) or RANGE (several stations, e.g. from 3 to 7)
e.g. softkey NUMBER

NUMB
ER
RANG
E
0[ :::n:
000
Display: "Station" - Key in "1"
GADOPT TABLE
Press ENTER
This tool is deleted from the tool table.
Press softkey ADOPT TABLE

ALL
Press softkey ALL
POSITION Using an accessory tool for leverage, remove the respective tool set
RIGHT
(station 1); if necessary, first press softkey POSITION RIGHT to move
the magazine into a more suitable tool change position.

ALL
FINISHED

Example 3: Tool change
Task
Transfer a tool from the magazine to the tool adapter.
Conditions □ The tool adapter is empty.

□ The desired tool is in the magazine (e.g. station 1) and must be listed
in the tool table.
□ Machine is in home position.
lrn;ol Activate main mode MDI
D
0
000
[ :::n:
Press softkey M
Key in "106"
G Press ENTER
D Press softkey []
G000
000
Press ENTER
Key in station number (e.g. 1)
G Press ENTER
Unlike M06, a check cycle is performed in M106 which is more

time-consuming.

Task
Transfer a tool from the tool adapter to the magazine.
Conditions:
Example 4: Tool change
□ The desired tool is in the tool □ The machine has been referenced.
adapter.
lrn;ol Activate main mode MDI
D 0
000
[ :::n:
Press softkey M
Key in "106"
G Press ENTER
D Press softkey []
G 000
000
Press ENTER
Key in "0"
(Remove the tool)
G Press ENTER
Unlike M06, a check cycle is performed in M106 which is more

time-consuming.

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Operator's manual

TRUMPF Maschinen GmbH + Co KG

This document was compiled by the Technical Documentation Dept. of

© TRUMPF Maschinen GmbH + Co KG

Before you continue ...

Contents of the □ Chapter 1: Safety

Handbooks on the programming systems and material for use in training

& The entire machine documentation contains vital safety information

B119E0 Before you continue... 0-5

2. Mechanical cutting processes.....................................................2-2

3. Tensile strength Rm of metallic materials..................................2-6

4. Tables of maximum capacities....................................................2-9

B119E0 Contents 0-7

6 Slotting tool (Option). . . . . . . . . 2-19

4. Oils and Lubricants....................................................................3-13

B119E0 Contents 0-9

2. Machine sub-assemblies . 4-3

5. Retractable Clamps (Option) . .4-22

6. Machining with scratch minimization . .4-29

7. Sensor stop pin. . .4-32

8. Reference Guides .4-33

0-10 Contents B119E0

1. Description of operating elements. . 5-2

2. Workplaces at the machine . .5-11

Part 2: Examples of operation ..

2. Program execution . . . . . . . . . . . . .5-17

B119E0 Contents 0-11

4. Service and diagnostic functions..............................................5-35

5. Solutions to problems: .5-40

6. Program Input and Output..........................................................5-43

7. Management of programs and tables........................................5-61

0-12 Contents B119E0

8.2 the linear magazine ........... .5-76

9. Job tables (SheetMaster linkage)..............................................5-87

2. Maintenance Overview. . 6-3

3. Machine lubrication . . . 6-5

4. Maintenance: Hydraulic machine components........................6-17

4.5 accumulator with nitrogen . . . . . . . . . . . .6-21

8119E0 Contents 0-13

6. Maintenance: Mechanical machine components.....................6-30

7. Maintenance: Electrical machine components.........................6-38

8. What to do after a collision......................................................... 6-41

9. Regrinding tools .6-42

1.14 Contents B119E0

Chapter 7 Interface Description

1.1 General information . . 7-2

1.2 Device control . . . 7-6

1.3 Interface selection . . 7-7

1.4 Technical data, signal leads 20 mA . 7-9

1.5 Technical data, signal leads V24 . . .7-10

B119E0 Contents 0-15

1.7 Pin assignment serial interface 1 20 mA ... 7-12

1.9 Input to the control from data media...................................7-16

Chapter 8 System messages

2. Measuring results . .. 9-5

3. Drawing: Workpiece................................................................... 9-6

4. Drawing: Location of measuring points................................9-7

1.16 Contents B119E0

2. Installation example . .9-11

3. Alignment procedure .9-11

B119E0 Contents 0-17

1.18 Contents B119E0

B119E1 Safety 1-1

With this declaration of EC conformity and the CE marking on the