Trubend 3000 Operator Manual

Operator's manual
TruBend Series 3000

Operator's manual
TruBend Series 3000
Edition: 11/2007
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and the date of the edition.
TRUMPF Werkzeugmaschinen GmbH + Co. KG

Technische Dokumentation
Johann-Maus-Straße 2
D-71254 Ditzingen
Tel: +49 (0) 71 56/3 03-0
Fax: +49 (0) 71 56/3 03-30 540
Internet: http//www.trumpf.com
E-mail: docu.tw@de.trumpf.com
This document was compiled by the Technical Documentation of TRUMPF

Werkzeugmaschinen GmbH + Co. KG.
All rights to this documentation, especially the right of reproduction and

distribution as well as translation are retained by TRUMPF Werkzeug-
maschinen GmbH + Co. KG, even in the case of notifications of protected
privilege. No part of the documentation may be in any way copied or processes
using electronic systems, reproduced or distributed without the prior written
consent of TRUMPF Werkzeugmaschinen GmbH + Co. KG. Errors excepted;
subject to technical modifications.
© TRUMPF Werkzeugmaschinen GmbH + Co. KG
TRUMPF Werkzeugmaschinen GmbH + Co. KG is not liable for any errors in

this documentation. No liability is accepted for direct or indirect damage
resulting from the delivery or use of this documentation, in so far as this is
legally permissible.
Contents
Chapter 1 Safety
1. For your safety............................................................... 1-3

1.1 TruBend Series 3000 in accordance with the EC
Machinery Directive ......................................................... 1-4
2. Terminology ................................................................... 1-6
3. Operational safety ......................................................... 1-7

3.1 Correct use ...................................................................... 1-7
3.2 Guidelines on electromagnetic compatibility (EMC)........ 1-8
3.3 Measures to be taken by the user/operator..................... 1-9
Danger signs and warnings ........................................ 1-9
Signage on the machine........................................... 1-11
Signage on the machine in the USA ........................ 1-12
Instructing personnel ................................................ 1-14
Duty of care when using the machine ...................... 1-16
Procedure in the event of malfunctions or
emergencies ............................................................. 1-17
Using the spare parts and operating materials
intended for the machine .......................................... 1-18
Water protection ....................................................... 1-19
3.4 Measures to be taken by the manufacturer ................... 1-20
4. Overview of dangers ................................................... 1-25
5. Workplaces................................................................... 1-27
6. Authorized personnel.................................................. 1-28
7. Safe operation, work safety instructions .................. 1-29
8. Confirmation ................................................................ 1-32
B561EN00.DOC Contents 0-5

Chapter 2 Installation conditions
Who does what?......................................................................... 2-3
1. Installation site............................................................... 2-4

1.1 Arrangement and space requirements of the
machines.......................................................................... 2-4
1.2 Floor requirements........................................................... 2-4
1.3 Weight load...................................................................... 2-5
1.4 Ambient conditions .......................................................... 2-6
2. Electrical supply ............................................................ 2-7

2.1 Power supply ................................................................... 2-7
2.2 Connected loads, fuse protection and frequency ............ 2-8
2.3 Network connection ......................................................... 2-9
3. Compressed air supply ............................................... 2-10
4. Operating material ....................................................... 2-12
5. Transport ...................................................................... 2-13

5.1 Customer preparations for transporting the
machine to the installation site ...................................... 2-13
Preparing auxiliary tools ........................................... 2-13
5.2 Unloading the machine, transporting it to the
installation site ............................................................... 2-14
Checking the damage in transit ................................ 2-14
Unloading and transporting the machine.................. 2-15
6. Planning aid ................................................................. 2-17
Chapter 3 Description
1. Machine concept............................................................ 3-3
0-6 Contents B561EN00.DOC

2. Technical specifications ............................................... 3-4
2.1 Machines.......................................................................... 3-4
2.2 Backgauges ..................................................................... 3-6
2.3 Machine axes................................................................... 3-7
3. The most important modules ....................................... 3-8

3.1 Machine body .................................................................. 3-9
3.2 Upper drive and hydraulic system ................................... 3-9
3.3 Beam................................................................................ 3-9
3.4 Crowning........................................................................ 3-10
Crowning slots with crowning blocks ........................ 3-10
Mechanical crowning ................................................ 3-11
Hydraulic crowning ................................................... 3-11
3.5 Control panel ................................................................. 3-12
T3000 VA control system ......................................... 3-13
3.6 Foot switch..................................................................... 3-15
3.7 Backgauge..................................................................... 3-16
2-axes backguage .................................................... 3-17
4-axes backgauge (optional) .................................... 3-17
3.8 Tool clamping ................................................................ 3-18
Manual tool clamping................................................ 3-19
TRUMPF Quick Clamp for upper tools (optional)..... 3-20
Pneumatic tool clamping (optional) .......................... 3-21
3.9 Standard support bracket .............................................. 3-21
4. Tools ............................................................................. 3-22

4.1 Tools from TRUMPF...................................................... 3-22
4.2 Programming the tools................................................... 3-23
5. The most important options ....................................... 3-24

5.1 Additional foot switch ..................................................... 3-24
5.2 Manual operator console ............................................... 3-25
5.3 Network connection ....................................................... 3-26
5.4 TRUMPF BendGuard .................................................... 3-26
Functions of the magnetic plate................................ 3-29
Indicator lamp on the transmitter .............................. 3-30
Safety notes.............................................................. 3-30
5.5 Light curtain ................................................................... 3-31

Chapter 4 Operation
1. Description of the operating elements ........................ 4-3

1.1 Foot switch....................................................................... 4-3
1.2 Manual operator console (optional) ................................. 4-4
1.3 Operating elements at the switch cabinet........................ 4-5
1.4 Operating elements for the control system...................... 4-8
1.5 User interface structure ................................................. 4-10
Programming mode .................................................. 4-10
1.6 Operating modes ........................................................... 4-10
Selecting or activating operating modes .................. 4-11
2. Switching on the machine .......................................... 4-12

2.1 Enabling EMERGENCY STOP...................................... 4-12
2.2 Switching on the machine.............................................. 4-13
3. Switching off the machine .......................................... 4-14

3.1 Switching off the machine in case of emergency or
malfunction .................................................................... 4-14
3.2 Switching off the machine.............................................. 4-14
4. Using Online help ........................................................ 4-15
5. Entering letters ............................................................ 4-15
6. Optoelectronic safety devices.................................... 4-16

6.1 Safety mode................................................................... 4-16
BendGuard mode ..................................................... 4-16
Light curtain mode .................................................... 4-18
6.2 Selecting the safety mode ............................................. 4-19
6.3 Operating the machine without optoelectronic
safety device.................................................................. 4-19
7. Loading a program ...................................................... 4-20
8. Creating a program...................................................... 4-21

8.1 Creating a program manually ........................................ 4-21
8.2 Interlinking two programs............................................... 4-22
8.3 Creating a program graphically (2D)
(drawing profile) ............................................................. 4-23

9. Modifying the program................................................ 4-26
10. Programming individual bends.................................. 4-26
11. Creating a tool.............................................................. 4-27
12. Program Management ................................................. 4-29
13. Tool data management................................................ 4-31
14. Changing the language ............................................... 4-33
15. Setting the program data ............................................ 4-33
16. Switching between MSC and ASV ............................. 4-34

16.1 Switching from ASV to MSC .......................................... 4-35
16.2 Switching from MSC to ASV .......................................... 4-35
16.3 Programming step change............................................. 4-36
17. Bending workpieces.................................................... 4-37
18. Bending workpieces step by step.............................. 4-38
19. Moving axes manually................................................. 4-39
Chapter 5 Setting work
1. Adjusting gauge finger.................................................. 5-3

1.1 Adjusting gauge finger for manual Z axis ........................ 5-3
2. Setting up tools.............................................................. 5-4

2.1 Loading upper tools ......................................................... 5-4
Loading upper tools with manual tool clamping ......... 5-5
Loading upper tools with TRUMPF Quick Clamp
(optional)..................................................................... 5-6
Loading upper tools in case of pneumatic tool
clamping (optional) ..................................................... 5-8
2.2 Loading lower tools.......................................................... 5-9
Loading lower tools with manual tool clamping .......... 5-9
Loading lower tools in case of pneumatic tool
clamping (optional) ................................................... 5-10

3. Segments of the upper tool holder ............................ 5-11
3.1 Dismantling segment ..................................................... 5-11
3.2 Installing segment.......................................................... 5-12

Dismantling BendGuard ........................................... 5-13
Installing BendGuard ................................................ 5-14
Setting the height of BendGuard .............................. 5-16
Checking the laser beam.......................................... 5-17
4.2 Light curtain ................................................................... 5-18
Aligning transmitter and receiver .............................. 5-18
Checking the function of the light curtain ................. 5-19
Chapter 6 Maintenance
1. General guidelines......................................................... 6-3
2. Maintenance overview................................................... 6-4
3. Lubrication ..................................................................... 6-5

3.1 Overview .......................................................................... 6-5
3.2 Maintenance instructions ................................................. 6-7
Hydraulic system ........................................................ 6-7
X axis guide rail ........................................................ 6-12
R axis guide rail ........................................................ 6-13
Ballscrew .................................................................. 6-14
Z axis guide rail......................................................... 6-15
4. Hydraulic components ................................................ 6-16

4.1 Overview ........................................................................ 6-16
4.2 Maintenance instructions ............................................... 6-17
Hydraulic hose lines ................................................. 6-17
5. Pneumatic components .............................................. 6-18

5.1 Overview ........................................................................ 6-18
Compressed air filter with water separator............... 6-19

6. Mechanical components ............................................. 6-21
6.1 Overview ........................................................................ 6-21
Upper and lower tool holders.................................... 6-22
Z axis guide rail......................................................... 6-24
Z axis toothed belt (with optional 4-axes
backgauge) ............................................................... 6-24
X axis fixed stop ....................................................... 6-25
7. Electrical components ................................................ 6-26

7.1 Overview ........................................................................ 6-26
Safety switch of the protective covers ...................... 6-28
Failsafe control system PCSS-F............................... 6-29
Electrical cables........................................................ 6-30
Switch cabinet........................................................... 6-31
Optoelectronic safety device .................................... 6-31
Chapter 7 Network card (optional)
Chapter 8 Index

Chapter 1
Safety
1. For your safety............................................................... 1-3
1.1 TruBend Series 3000 in accordance with the EC
Machinery Directive ......................................................... 1-4
2. Terminology ................................................................... 1-6
3. Operational safety ......................................................... 1-7

3.1 Correct use ...................................................................... 1-7
3.2 Guidelines on electromagnetic compatibility (EMC)........ 1-8
3.3 Measures to be taken by the user/operator..................... 1-9
Danger signs and warnings ........................................ 1-9
Signage on the machine........................................... 1-11
Signage on the machine in the USA ........................ 1-12
Instructing personnel ................................................ 1-14
Duty of care when using the machine ...................... 1-16
emergencies ............................................................. 1-17
Using the spare parts and operating materials
intended for the machine .......................................... 1-18
Water protection ....................................................... 1-19
3.4 Measures to be taken by the manufacturer ................... 1-20
B561EN01.DOC 0BSafety 1-1

4. Overview of dangers ................................................... 1-25
5. Workplaces................................................................... 1-27
6. Authorized personnel.................................................. 1-28
7. Safe operation, work safety instructions .................. 1-29
8. Confirmation ................................................................ 1-32
1-2 0BSafety B561EN01.DOC

1. For your safety
The TruBend series 3000 is a press brake. It is state-of-the-art and

reliable.
The machine is available in the following versions:

• As a fully secured complete machine in compliance with all
requirements of the EC Machinery Directive. These machines
are supplied with CE marking as well as EC Declaration of
Conformity.
• As a basic machine:
– without optoelectronic safety device.
– With the maximum Y closing speed of the beam of
220 mm/s (Y axis).
– With an unrestricted travel speed of the backgauge with
automatic movement triggering (X, R and Z axes).
Note
Due to safety regulations, the press brake may not be supplied and
operated as a basic machine within the European Union and the
associated countries.
Securing the basic machine If the machine is supplied and operated as a "basic machine", then
there will be certain hazards connected with the operation of the
machine, such as:
• Unsecured danger zone.
• Danger due to crushing.
The machine must be secured in accordance with the safety

regulations currently applicable in the country of operation.
Contents of the operator's This operator's manual describes the "completely secured
manual machine" version.
B561EN01.DOC 1BFor your safety 1-3

1.1 TruBend Series 3000 in accordance
with the EC Machinery Directive
With the EC declaration of conformity and the CE identification

marking on the machine, we confirm that the TruBend complies
with the basic safety and health requirements outlined in the EC
Machinery Directive 98/37/EC or in the USA ANSI B11.3-2002 and
OSHA 29 CFR Part 1910.
Fig. 52396en
The CE marking is at the front of the machine on the left-hand side

of the machine body.
The machine can nevertheless still be a source of danger if it is

operated inappropriately or used for purposes other than the
intended by insufficiently trained personnel.
We, the manufacturers of the machine, would like to introduce you,

the owner, to the safety concept of the machine and point out
potential hazards and remedial measures with the help of an
extensive chapter on safety. Particular emphasis has been put on
information about measures to be taken by the user/operator and
the manufacturer and the overview of hazards, including additional
measures to be taken by the customer.
All the following safety information must be read and understood

by everyone who works with the press brake or has responsibility
for it.
1-4 1BFor your safety B561EN01.DOC

Note
In addition to the information given here, observe the generally
applicable safety and accident prevention regulations of the
relevant country as well as the Federal and regional safety laws.
For the USA:

TRUMPF recommends that the safety regulations for press brakes,
standard ANSI B11.3 should be read and understood. A copy of
this standard is included in the technical documentation for your
machine (CD-ROM). Further copies can be requested from:
Association for Manufacturing Technology
7901 Westpark drive
McLean
Virginia
22102-4206
B561EN01.DOC 1BFor your safety 1-5

2. Terminology
Danger zone ... is the area within and around the machine in which the safety or
health of a person is at risk due to staying in this area. The danger
area must be secured using the appropriate safety equipment.
The user/owner ... is the person in whose premises the machine is installed and
operated.
Operator/personnel ... are the persons responsible for transport, installation, startup,
operation, maintenance, including cleaning and elimination of
malfunctions on the machine.
1-6 2BTerminology B561EN01.DOC

3. Operational safety
The machine is state-of-the-art and reliable.
However, due to the large number of clamping points, this machine

may be a source of danger if it is operated by untrained personnel
or if incorrectly operated. This may result in:
• Dangers to the safety of the operator, e.g. crushing or
amputation of the arms, hands, fingers or other body parts.
• Impairments to the machine and other property of the user.
• Impairment of the working efficiency of the machine.
3.1 Correct use
The TruBend Series 3000 are CNC-controlled press brakes for

bending cold metal sheets by forming.
The following machining operations are not permitted with

TruBend Series 3000:
• Processing hot or splintering materials.
• Cutting operations with non-specified tools.
Loading and removing The machines are designed as standard for operation by one
workpieces manually person (also see Section 5: Workplaces and Section 6: Permissible
operators, page 1-28).
The machines can also be operated by two persons. A second foot

switch must thus be provided.
B561EN01.DOC 3BOperational safety 1-7

Positioning workpieces The workpieces are correctly positioned if, from the point of view of
correctly the operator, they are at least 50 mm in front of the bending line
before the backgauge moves to the next stop position. This de-
finition is applicable in combination with "Automatic Safety Travel
Speed System" (ASV).
If other backgauge traverse modes are used, other tool positions

selected by the operator can also be correct, if these prevent
collisions with the moving backgauge in a similar manner.
Operating a machine with If the machine is converted to robot loading, the machine's stan-
a robot dard protection systems are not sufficient. The machine including
the robot must be additionally secured in compliance with the
relevant safety regulations to prevent:
• Access from outside.
• Parts getting out from the inside.
No liability for unintended Any other form of use is regarded as other than intended. The
use! manufacturer is not liable for any resulting damage. The owner
bears the sole responsibility for risk in such cases. The machine
guarantee is voided.
Authorized application also includes complete adherence to the

installation, operation, transport and maintenance conditions speci-
fied by the manufacturer.
Avoid any operations which could impair safety.
Alterations to the machine The user or operator is not allowed to make any unauthorized
alterations to the machine or retrofit it. The manufacturer assumes
no liability for any consequential personal injury or material
damage.
3.2 Guidelines on electromagnetic

compatibility (EMC)
Use the machine only within The electrical and electronic devices and components used in the
the industrial sector machine comply with the EMC guidelines and the European EMC
standards. The machine may not be used other than in the
industrial sector in accordance with EMC standards.
The declaration of conformity supplied together with the machine

confirms its compliance with guidelines and standards.
1-8 3BOperational safety B561EN01.DOC

3.3 Measures to be taken by the
user/operator
Danger signs and warnings
When operating the machine, actions need to be taken which are

potential sources of danger. Instructions for conducting such pro-
cedures are preceded by a warning in this operating manual.
Suitable danger signs are also placed on the system (see "Signage
on the machine", p. 1-11 and "Signage on the machine in the
USA", page 1-12).
Note
Please observe the warnings!
Follow the dos and don'ts given in the warnings. They are for your
safety.
These warning contain:
• A symbol.
• A signaling word.
• Information about the source and type of danger.
• Instructions on how to avoid the danger.
The form and content of the warnings are described in the

following sections.
Symbols
Warnings are supplemented by a symbol in the left column,
indicating the type of danger.
A general danger symbol. The type of danger is further specified in

the corresponding hazard warning.
This symbol indicates dangerous electrical voltage.
Signaling words
Warnings are indicated by one of the following signaling words:
• Danger
• Warning
• Caution

The signaling words mean the following:
Danger ... indicates a very serious danger. If not avoided, it could result in
death or serious injury.
Warning ... indicates a dangerous situation. If not avoided, it could result in

serious injury or significant material damage.
Caution ... indicates a potentially dangerous situation. If not avoided, it

could result in minor injuries or damage.
Information about the source and type of danger and how to

avoid it
The warnings contain information on the source and type of danger
and instructions on how to avoid it.
Example:
Unfiltered oil can destroy the hydraulic system!

Warranty claims are rendered void.
¾ Use filters with 3 μm pores to prefilter new oil.
Caution

Signage on the machine
The following signs indicate dangers concerning the operation of

the press brake:
Dangers concerning the operation of the press brake Fig. 32650
Note on freeing trapped persons with the Fig. 39136

EMERGENCY-UP foot switch

Signage on the machine in the USA
Dangers related to the operation of the press brake Fig. 33155

and additional information
Information about the danger zone Fig. 49011

Note that operators should not put their hands Fig. 33180
between the tools
Notice that the machine is top-heavy Fig. 33181
Safety information on operating a press brake Fig. 33182

Notice to avoid head injuries Fig. 33183
Instructing personnel
Instructing personnel Only authorized, trained, and instructed personnel may be

entrusted with the operation, maintenance and servicing of the
machine. They must receive special instructions on how to deal
with potential hazards. This is particularly applicable to work on
electrical and pneumatic equipment, which may only be carried out
by specialists.
Read the machine Anyone authorized by the user to operate, service and repair the
documentation machine must read and understand the technical documentation of
the machine. We recommend that the user has this confirmed in
writing by the respective personnel.
Defining responsibilities The responsibilities concerning operation, maintenance and repairs

must be clearly defined and adhered to in order to avoid any
confusion as regards the safety.
Working safely • The operator must always ensure that tools, press brake and
backgauge are set correctly for the current job.
• At least two idle strokes must be carried out before each shift
and each new job.
• The operator must ensure that there is nobody in the area of
the backgauge.
• The operator must ensure that everybody is well away from the
press brake and the workpiece before the press brake is used.

• When the machine is being operated by more than one person,
it must be ensured that neither the operator nor other people
are in the danger zone.
• When workpieces are being bent in the machine, the operator
must ensure that all back stops are correctly set.
• Before the press brake is used, the machine must be checked
to ensure it is in a proper condition:
– Are the tools worn?
– Are the machine covers and protective devices in the right
place?
• The operator must report any doubtful condition or any
necessary repairs to the owner.
• When leaving the machine (for details, see chapter
"Operation"):
1. Move the beam right down.
2. Press HYDRAULIC SYSTEM OFF.
3. Turn the main switch on the switch cabinet to 0.

Duty of care when using the machine
Only operate the machine if it The user and the persons in charge are under obligation to operate
is in perfect working order the machine only when it is in perfect working condition.
The user must install the machine in accordance with the
installation plan and installation conditions.
The operator should also ensure that only authorized persons work
at the machine.
Safe work station The user must ensure that the machine workstation is maintained
in a clean and orderly condition by issuing appropriate instructions
to this effect.
The front side of the beam is not to be misused for hanging up
tools.
Wear protective clothing Appropriate protective clothing must be worn at all times. The user
must make it compulsory for the personnel to wear protective
clothing, gloves, safety shoes and safety glasses if necessary.
Baggy and loose clothing may not be worn.
Checking the danger zone The operator must always make sure nobody is within the danger
zone before starting up the machine.
Check the tooling status The fitter of the machine is responsible for the tooling status. The
fitter must check the tooling status prior to operation of the
machine to avoid any risks due to an incorrect tooling status.
Report defects and damage The operator is obliged to immediately report any changes to the
machine (including its operating performance) which impair safety
to the user. Therefore, check the machine for visible defects and
damage at least once per shift.
Checking safety devices and Neither the user nor the operator is permitted to dismantle any
keeping them in working safety devices or remove them from service.
order If maintenance or repairs make it necessary to dismantle safety
devices or remove them from service, these safety devices must
be reinstalled or restored to service immediately after this work is
completed.
Not all workpieces can be machined with the standard protective
equipment. In such cases, contact the manufacturer or provide
additional safety precautions.

Observing the shutdown Unless stipulated otherwise, the machine should be switched off at
procedure the MAIN SWITCH for any setting, maintenance or repair work.
The MAIN SWITCH can be additionally secured with a padlock.
Note
The national accident prevention regulations should be adhered to,
irrespective of this operating manual.

emergencies
EMERGENCY STOP and If a fault occurs during a machine operating process, the operator
EMERGENCY-UP should use his or her expertise to determine whether immediate
activation of the EMERGENCY STOP switch is required or whether
the EMERGENCY-UP button on the operating station (beam
moves upwards) should be pressed.
Press the EMERGENCY-UP • If a person's limb gets trapped in the machine.

foot switch • If there is a danger of parts of the body getting caught in the
machine.
PRESS EMERGENCY STOP In all other situations.
Shut down using the The machine should be shut down by means of the MAIN SWITCH
MAIN SWITCH if maintenance or repair work has to be carried out which goes
beyond eliminating temporary malfunctions. The MAIN SWITCH
can be additionally secured with a padlock.

Using the spare parts and operating
materials intended for the machine
Use original parts The original parts and accessories are specially designed for the
machine. Spare parts for original parts and accessories other than
those supplied by the manufacturer of the machine have not been
checked and approved by the manufacturer. Installing and/or using
such products may therefore alter design-specific properties of the
machine and impair safety.
Liability disclaimer The manufacturer assumes no liability for any damage resulting
from the use of non-original parts and accessories or from the
inappropriate installation or replacement of original parts and
accessories.
Instructions for using The instructions for using operating materials (particularly
operating materials lubricants) should be observed. The following instructions are
binding, if a manufacturer's safety specifications sheet (European
Directive 91/155/EEC, 93/112/EC; USA: MSDS Sheet according to
OSHA §1910.1200 (g)) is prescribed for an operating resource:
• Chemical properties.
• Physical and safety-related specifications.
• Transport
• Regulations
• Safety measures, storage, and handling.
• Measures in the event of accidents or fires.
• Toxicological information.
• Ecological specifications.
This is particularly applicable for the appropriate disposal of

operating materials. The prescribed disposal methods and the
waste code are specified in the safety specifications sheet. Safety
data sheets can be obtained from the manufacturers of the
respective operating materials.

Water protection
In the Federal Republic of Germany, the principle of precaution

applies to all machines that use materials which could pollute
water. This principle states that no water contamination may result
from the use of such substances. This is the main point of §19 of
the Water Resources Act (WHG). The plant decrees (VAwS) and
administrative regulations (VVAwS) of the Federal States specify
how to adhere to this principle of precaution.
Water-pollutant substances Hydraulic oil and lubricants

Water hazard class WGK 2
Hydraulic oil operating pressure 350 bar
Volume of the water-pollutant substances ≤1000 l
Hazard level of the entire system A
Tab. 1-1

3.4 Measures to be taken by the
manufacturer
The machine may only be operated with using appropriate safety

devices used to secure the danger zone.
Safety measures for the The machine is equipped with the following safety measures for
danger zone the danger zone:
• Optoelectronic safety devices: TRUMPF BendGuard or light
curtain.
• Operating modes "Foot operation" and "Two-foot operation"
(foot operation by two operators) with a rapid speed of
220 mm/s only in combination with an optoelectronic protective
device.
• Safety doors on the sides and a roller gate at the back to
secure the danger zone, including special safety locking
mechanisms.
• Safety control system.
• Robot switch in switch cabinet.
• Manual adjustment of gauge finger without reaching into the
danger zone in the machine.
• EMERGENCY STOP and foot switch EMERGENCY-UP.
Optoelectronic safety device Working at a rapid speed >10 mm/s is permitted only when an
optoelectronic protective device is used.
The optoelectronic protective device must be available at the
machine as a mandatory addition in the countries of the European
Union and other countries with similar laws.
TRUMPF offers the following optoelectronic protective devices:

• TRUMPF BendGuard.
• Light curtain.
TRUMPF BendGuard TRUMPF BendGuard enables work at rapid speed without im-
pairing the safety of the operating personnel. To ensure this, the
area underneath the upper tool is constantly monitored by two
bands of three visible red laser beams, which move along with the
machine. If the light beams are interrupted, the downward move-
ment of the beam is stopped.
Light curtain The light curtain is an optoelectronic protective device and enables
work at rapid speed without impairing the safety of the operating
personnel.
The light curtain is attached in front of the beam and table and
protects against obstacles from a length of 14 mm. If the light
curtain is interrupted, the beam stops and moves to the upper dead
center in order to avoid injuries. The movement of the beam then
needs to be actively restarted.

"Foot operation" mode In "foot operation", the beam of the machine can move downwards
only at slow working speed (1-10 mm/s). In combination with the
optoelectronic protective device, the beam can however move
down (as far as the mute point) at rapid speed (220 mm/s). The
optoelectronic protective device stops the descending movement
of the beam if the operator reaches into the danger zone.
• When switching the operating mode from one to two
operators, the change of operating mode must be confirmed by
both operators with the BEAM DOWN foot switch.
• When switching the operating mode from two to one operator,
the change of operating mode must be confirmed by both
operators with the BEAM DOWN foot switch.
"Two-hand operation" In the two-hand operation, the beam can move down (as far as the
operating mode (optional) mute point) at rapid speed (>10 mm/s).
Manual increment switching After every bend, the approach to the next position of the
(MSC) backgauge must be initiated by pressing the foot switch.
• When operated by just one person, manual jog movement is
possible with the active foot switch BEAM DOWN.
• When operated by two persons, both operators need to
approve the manual jog movement by pressing the BEAM
DOWN foot switch.
Note
If only once switch is selected at the control system, then no stroke
is triggered when the second foot switch is actuated.
Automatic safety travel speed The rear stop moves automatically to the next stop position at the
system (ASV) end of the bending operation:
• If the target point of the rear back stop axis (X, R, Z) is within a
defined safety range, the relevant backgauge moves to the
stop position in the Y direction at maximum speed. The danger
of squeezing and crushing is avoided by a hinged rear stop
finger. All other axes of the backgauge move with reduced
speed.
• If the start and target points are located outside the defined
safety range, then the rear stop moves directly to the stop
position with maximum speed.
Note
If it is not possible to work with the "Automatic Safety Path System"
(ASV), then a corresponding message will be displayed on the
user interface. The "Manual increment switching" (MSC) method
must be traversed in such cases.

Protective interlock devices The protective interlock devices (in particular the roller gate at the
rear and the safety doors on the sides) for securing the danger
zone of the machine are effective in all operating modes of the
control system.
If a sequestering protection device was previously opened, the

operator must assure himself that there is nobody in the danger
area secured by the protection device before restarting the
machine.
If the rear roller gate is opened during machine operation:

• The beam stops.
• All drive motors are stopped.
• All CNC-controlled axes are stopped.
Opening the roller gate during operation of the machine is

considered the same as pressing the EMERGENCY STOP. The
machine cannot be restarted until all doors are closed.
If the side safety doors are opened during operation of the

machine:
If one of the side safety doors is opened during operation:

• The beam can still move with reduced speed (max. 10 m/s)
after the BEAM DOWN or START foot switch is pressed.
If both the side safety doors are opened during operation:

• The beam stops.
• All drive motors are stopped.
Note
The protective interlock devices (side safety doors, but also the
covers of the hydraulic cylinder) are made partially of polymethyl-
methacrylate (impact-resistant acrylic glass). This material can age
as the result of environmental effects (become brittle). The owner
must therefore check regularly that this material is still fulfilling its
protective function.

Safety control system The safety control system complies with the requirements of
Category 4 of EN 954-1:
• A single error in the control system will not lead to the loss of
the safety function (single error security).
• If possible, the safety function recognizes an error either during
or before the next request from the safety function.
• An accumulation of errors should not normally lead to the loss
of the safety function.
The safety functionalities thus remain operational when an error

occurs. The error is recognized in time to prevent a loss of the
safety functions.
Safety is ensured by the following:

• Safety control system.
• Tested software modules.
• Use of double-channel outputs (e.g. for a high speed valve).
The software version can be seen on the display of the safety

control system.
Note
The manufacturer accepts no responsibility for use of the safety
control system software on other machines or for any improper use
of the software.
Robot switch in switch The control connection between the robot and the press is on the
cabinet same plug in the switch cabinet as for operating station 1. The
operating station must be out of the press area.
The robot switch in the switch cabinet has two settings:
• Setting 0: Beam travels without optoelectronic protective
device at reduced speed ≤10 mm/s.
• Setting 1: Robot operation.
The position of the robot switch is monitored: the beam moves
to position 1 at rapid speed only if a robot is connected to a
plug. If operating station 1 is connected, the beam only travels
to position 1 at reduced speed even with the robot switch at
setting 1.
Manual backguage finger During manual repositioning of the gauge fingers, they move to a
adjustment safe tooling position for the operator in front of the tool level. The
operator does not need to reach through the tool level.

EMERGENCY STOP EMERGENCY STOP devices are at several points of the machine:
• EMERGENCY STOP impact button on the foot switch.
• EMERGENCY STOP on the control panel.
• EMERGENCY STOP function of the foot switch BEAM DOWN
(EMERGENCY STOP function of the foot switch is triggered by
pressing the foot switch with a force of at least 220 N).
• EMERGENCY STOP impact button on the foot switch 2
(optional).
• EMERGENCY STOP impact button on the two-hand console
(optional).
Activating EMERGENCY STOP affects the following machine

functions:
• Interruption of the power supply of the machine (24 V control
voltage is retained at the machine).
• Beam movement stops, the hydraulic unit is switched off.
• All CNC-controlled axes stop moving.
Foot switch EMERGENCY-UP An EMERGENCY-UP foot switch is located on the foot switch or
the two-hand operator console. The beam can be moved up as far
as the upper dead point by pressing this foot switch.

4. Overview of dangers
The following overview of hazards is a summary of the main

potential threats to life and limb posed by the machine. No risk to
personnel can be expected thanks to the design and construction
of the machine, along with its safety devices, which are in
compliance with the EC Machinery Directive 98/37/EC or in the
USA, ANSI B11.3-2002 and OSHA 29 CFR Part 1910.
Additional measures that can be taken by the user to reduce any
residual risks are specified in the overview of hazards.
Type of hazard Dangerous point Danger Additional precaution

Mechanical hazard
Due to crushing, cutting, striking or • Working movements of Risk of injury • Operation by trained
having body parts sheared off. the press beam with and instructed
upper tool. personnel.
• Movement of the back- • Wear personal pro-
gauge and workpiece. tective gear (work
• Vertical tool change. gloves, safety shoes.
• Collision of the backgauge
with upper or lower tools.
• Stopping and positioning
of the workpieces.
• Movement of the work-
piece during and after
machining.
Risks due to emission of gasses • Bursting of pneumatic Risk of injury • Operation by trained
with high pressure (in case of lines or hoses. and instructed
optional pneumatic tool clamping). personnel.
Danger due to falling workpieces. • Releasing the workpiece Risk of injury • Operation by trained
after bending. and instructed
personnel.
• Use support brackets.
• Wear safety shoes.
Hazards due to instability. • Tipping over of the Danger of death, • Anchor the machine to
machine. danger of injury the floor.
• Use load suspension
points for transport,
installation, and
disassembly of the
machine (for load
suspension points, see
chapter 2 "Installation
requirements").
B561EN01.DOC 4BOverview of dangers 1-25

Type of hazard Dangerous point Danger Additional precaution
Electrical hazard
Due to electrical contact. • Direct contact with parts Risk of fatal injury • Specially trained
which are normally live. personnel for
• Indirect contact with parts maintenance/servicing/
which are live due to a repairs.
malfunction.
Hazards due to substances
Contact with or inhaling of toxic • Oily compressed air. Health risk • Use oil-free
fluids, gases, mist or fumes. • Lubrication and cleaning compressed air.
when putting the machine • Ventilate the
into service. workplace sufficiently.
• Observe the notes in
the operating manual.
Tab. 1-2
1-26 4BOverview of dangers B561EN01.DOC

5. Workplaces
The TruBend Series 3000 has been designed for operation by one
or two persons.
No other persons are permitted to be present in the danger zone of
the machine during operation.
Equivalent continuous sound The A-rated equivalent continuous sound pressure level at the
pressure level <70 dB(A) workstation of the operating personnel is no higher than 70 dB(A).
B561EN01.DOC 5BWorkplaces 1-27

6. Authorized personnel
Operating the machine The operating personnel must be instructed by qualified specialists
before working at the machine. The instruction manual should be
given to the operating personnel to be read.
Transporting, installing and Qualified specialists (e.g. trained mechanics).

removing machines
Machine servicing, Qualified specialists (e.g. trained mechanics).

maintenance
Checking safety devices Qualified specialists (e.g. trained mechanics).
Electrical work Qualified electrician.
1-28 6BAuthorized personnel B561EN01.DOC

7. Safe operation, work safety
instructions
Beam moves downwards.

Amputation of body parts possible.
¾ Never insert hand between upper and lower tools.
Warning
Fig. 25903
B561EN01.DOC 7BSafe operation, work safety instructions 1-29

Workpiece limbs fold upwards during bending and then back
again after bending is complete!
Risk of injury.
Warning ¾ Workpiece should be gripped only from the side.
Fig. 25904
Fig. 25905
1-30 7BSafe operation, work safety instructions B561EN01.DOC

Workpiece sides fold upwards during bending!
Risk of injury.
¾ Maintain sufficient distance between yourself and the
Warning workpiece.
Fig. 25906
Workpieces having sharp edges!
¾ Wear personal protective gear (gloves, safety shoes, safety

Caution glasses).
Immediate discharge of the beam!

Risk of injury due to flying workpieces, bursting hydraulic
lines, damage to hydraulic cylinder seals or hydraulic valves.
Warning ¾ For special applications (e.g. punching, cutting): obtain the
manufacturer's approval.
¾ Observe the bending instructions (e.g. match the sheet size
to the die width of the lower tool).
B561EN01.DOC 7BSafe operation, work safety instructions 1-31

8. Confirmation
If required, the user/owner can be given written confirmation that

the personnel have read and understood this chapter on safety.
This chapter on safety information must be annually read and
understood by everyone who works with the press brake or has
responsibility for it.
Signature Date
Tab. 1-3
1-32 8BConfirmation B561EN01.DOC

Chapter 2
Installation conditions
Material number: 0366209
B561EN02.DOC Installation plans - Version 3 2-1

1. Installation site............................................................... 2-4
1.1 Arrangement and space requirements of the
machines.......................................................................... 2-4
1.2 Floor requirements........................................................... 2-4
1.3 Weight load...................................................................... 2-5
1.4 Ambient conditions .......................................................... 2-6
2. Electrical supply ............................................................ 2-7

2.1 Power supply ................................................................... 2-7
2.2 Connected loads, fuse protection and frequency ............ 2-8
2.3 Network connection ......................................................... 2-9
3. Compressed air supply ............................................... 2-10
4. Operating material ....................................................... 2-12
5. Transport ...................................................................... 2-13

5.1 Customer preparations for transporting the
machine to the installation site ...................................... 2-13
Preparing auxiliary tools ........................................... 2-13
5.2 Unloading the machine, transporting it to the
installation site ............................................................... 2-14
Checking the damage in transit ................................ 2-14
Unloading and transporting the machine.................. 2-15
6. Planning aid ................................................................. 2-17
2-2 1BInstallation site - Version 3 B561EN02.DOC

Who does what?
Customer Before the machine is delivered, you must make sure that all of the
conditions described in this chapter have been fulfilled.
Otherwise, TRUMPF's service personnel will not be able to put the
machine into service.
Note
The MAIN SWITCH of the machine may be switched on only by
TRUMPF Service personnel.
TRUMPF Service The machine is put into service by TRUMPF Service technicians.
This includes:
• Installing, aligning, leveling and securing the machine.
• Filling in the hydraulic oil.
• Connecting the machine to the supplies (except the electrical
power supply).
• Conducting a functional test.
• Instructing personnel.

20
1. Installation site
1.1 Arrangement and space requirements

of the machines
The arrangement of the machines and their space requirements

with standard installation can be found in the currently valid
installation plan.
Installation plans contain information about the following:

• Arrangement of individual options.
• Space requirements for opening all doors.
• Swiveling range of the control panel.
• Outside dimensions of the protective cover and space require-
ments for the protective cover when it is opened.
• Electric power supply.
• Pneumatic connection.
1.2 Floor requirements
Evenness of the installation • The floor should be as even as possible.

surface • Height variation, maximum 10 mm/0.39 in.
Installation surface Quality of the entire installation surface for the machine with switch
cabinet:
• Base plate throughout the area of the load-bearing points.
• Smooth surface without expansion joints or cracks, particularly
in the area of the wedges.
• The floor must be oil-proof.
Attention must be given to variable loads in the immediate vicinity

of the machines (e.g. fork lifts, assembly and disassembly of
machines directly beside the press brake, shuttle carts, etc.).

Elastic base plate • Minimum thickness 200 mm/7.87 in.
• Crosswise reinforcement 3.7 cm2/m, double-layered.
• Concrete quality (equivalent to tensile strength C 25/30):
– Cylinder compressive strength ≥20 N/mm2.
Ceiling plate/ If the machine is installed on a ceiling plate or free-span base

free span base plate plate, a structural analyst must carry out an evaluation, taking into
account the details in the "Weight Load" (see section 1.3, p. 2-5).
• Load capacity 15 kN/m2.

• Minimum thickness 200 mm/7.87 in (for load capacity 15
kN/m2).
• Concrete quality (equivalent to tensile strength C 25/30):
– Cylinder compressive strength ≥30 N/mm2.
• Multiple span girders.
Note
If these requirements are not fulfilled, a structural analyst must
carry out an evaluation.
1.3 Weight load
Structural stress analysis Subject the load-bearing capacity of the floor surface to a structural
stress analysis prior to installation.
Weights of the relevant machine parts and load on the support

points:
3066 3120 3180

Total weight of the machine [kg] 5400 8300 13200
Weight on each support point at [kg] 2070 2880 4900
the front
Weight on each support point at [kg] 630 1270 1700
the rear
Weight support per base on a [mm2] 160 x 200 160 x 200 160 x 200
surface area of ...
Tab. 2-1

1.4 Ambient conditions
Ambient temperature of the Permissible ambient temperatures for the operation of the
machine machines:
• +10°C/+50°F to +40°C/+104°F.
• According to NFPA 79, the maximum temperature in the USA
and Canada is 40°C/104°F.
Ambient conditions for the Permissible temperature range for the control system during
control system transport or when the machines are switched off:
• -20 °C/-4 °F to +70 °C/+158 °F.
Acceptable humidity for the control system during transport or

when the machines are switched off:
• 20 to 75 % relative air humidity.
• 90 % temporarily, but non-condensing.
Damp rooms are not suitable for the operation of control systems
since the contactor and relay contacts may become corroded,
resulting in control system errors.
Hydraulic system Permissible operating temperature (oil temperature):

• maximum +80 °C/+176 °F.
Permissible temperature range for pumps, hydraulic components,

and seals:
• -20 °C/-4 °F to +80 °C/+176 °F.

2. Electrical supply
2.1 Power supply
Continuous undervoltage or overvoltage is not permitted. Greater

voltage fluctuations endanger the problem-free operation of the
machines and reduce their performance.
NEC conditions Note

The NEC applies only to Canada and the USA.
Grounding The machine and power distributor system must be equipped with
a grounding line in accordance with NEC article 250, "Grounding".
For details on grounding power distributor systems and industrial
plants, refer to the NEC standards or consult an electrician or the
power station.
Grounded power supply with Power supply lines in ungrounded power supply systems with delta
star connection connection are not fail-safe by nature. Delta power supply systems
tend to generate transient overvoltage to ground. Delta power
supply systems can result in increased voltages being applied to
the connected devices. The control system or machine can no
longer be operated reliably if a potential to ground occurs in the
system. For this reason a grounded transformer must be installed
in the star connection in delta power supply systems (see NEC
article 450-5).

2.2 Connected loads, fuse protection and
frequency
Machines may be connected only by qualified specialists.
Connected loads Before delivery, the system is set to the power supply voltage and
frequency specified by the customer.
TruBend 3066, 3120 3180

Line voltage [V] 3x220 3x400 3x460 3x220 3x400 3x460
Power supply voltage tolerance - ±5 % ±5 %
Frequency tolerance - ±2 % ±2 %
Connected load [kW] 10.9 13.2 14.7 18.5
Fuse protection (small) [A] 3x50 3x35 3x35 3x80 3x50 3x50
Maximum interruption time - 10 ms every 10 s
Tab. 2-2
Connecting cables Establish the electric power supply in accordance with DIN EN
60204-1/4.3.1:
Cables Four-pole copper cables (L1, L2, L3, PE)

Cable cross-section Design in accordance with:
VDE 0100, Part 430 (IEC 364-4-47)
Ground wire Design in accordance with:
VDE 0100, Part 540 (IEC 364-5-54)
Tab. 2-3
NEC conditions Note

The NEC applies only to Canada and the USA.
• A four-pole connection is required: L1, L2, L3 and PE.

• THHN copper or equivalent is recommended (2000 V maximum
output) designed for a maximum temperature 90°C/194°F.
• No aluminum cables may be used to connect the machine.
• The conductor cross-section must correspond to NEC 670-4 (a),
with a permissible amperage of at least 125 % of the operating
current specified on the nameplate.
• To ensure voltage stability and rating, the line dimension
should be larger than specified in the NEC table 310-16.
2-8 2BElectrical supply - Version 3 B561EN02.DOC

2.3 Network connection
TRUMPF provides the following interfaces for the network (e.g. a

connection to a programming system) in the control cabinet of the
machine:
• RJ 45 plugs for customers with shielded-twisted pair network
cabling.
Establishing an alternating If several machines are to be connected to the network, a per-

current supply for the sonnel switch (network distributor) is necessary. The network
personnel switch distributor must be supplied with AC current by the customer,
because the distributor must also function when the machine is
switched off.
Note
The same nominal voltage and frequency tolerances as those for
the machine are applicable when using a personnel switch
(network distributor) (see "Connected loads, fuse protection and
frequency", p. 2-8).
Provision of power supply • Worldwide (outside the USA and Canada): 230 V with
grounded socket or in accordance with the receptive national
standard.
• USA and Canada: 115 V with plug socket according to USA
standard.
Note
For more information on network cabling, see chapter 8.

3. Compressed air supply
Note
Compressed air supply is required only in machines with
pneumatic tool clamping (optional).
Requirements for the • The compressed air connection may be flexible or constructed
compressed air network as permanent tubing to the machine.
• Equip the compressed air connection with a manually-operated
3/2-directional control valve with ventilation at the machine
end.
• The supply line should be supplied directly from the main line.
Customers should supply a stopcock for this.
Connected loads Property Requirement

Required system pressure 6 bar
Min. nominal diameter of the supply line 13 mm (1/2")
Min. nominal diameter of the main line 13 mm (1/2")
Air consumption (required volume rate of approx. 0.1 m3/h
flow according to ISO 1217 or DIN 1945)
Length of the connecting line No limit
Tab. 2-4
Properties of the compressed Property Requirement Quality Recommendation

air at the tapping point class
(ISO 8573-1)
Condensate- Cooled to 5 Cold dryer
free +7°C/+44.6°F
(pressure dew point)
Dust-free Max. particle size: 4 Air filter in front of
15 μm the system
Max. particle density:
8 mg/Nm3
Oil-free Max. oil content: 4 Compressing
5 mg Nm3 compressors as
low-oil or oil-free
as possible
Tab. 2-5
2-10 3BCompressed air supply - Version 3 B561EN02.DOC

Maintenance unit A maintenance unit (filter regulator B07) is mounted on the
machines:
TruBend Series 3000 pneumatic system maintenance Fig. 44597

unit
Insufficient compressed air Connecting a suitable compressor to the cold dryer and microfilter
network? combination to the machine:
Maximum compressor-to-machine distance: 50 m

Min. nominal diameter of pipelines 1"
Tab. 2-6
The cold dryer keeps the compressed air free of condensation.

The microfilter combination filters solid contamination in the first
stage and absorbs oil fumes in the second stage.
Distance to the compressor Condensation water can form with distances >50 m:
>50 m • Provide the machine with an air reservoir with a holding
capacity of a maximum of 20 liters.
• Secure the air reservoir from the network with a non-return
valve.
Additional recommendations Additional recommendations for the use of compressors, cold

dryers and microfilter combinations can be obtained upon request.

4. Operating material
Hydraulic oil
Only filtered oil may be used to fill oil reservoirs in the machine
hydraulic system. Filters must have a filter pore size of 3 µm.
Any of the following hydraulic oils can be used:

• Aral Vitam DE 46
• BP Energol HLP-D 46
• Castrol Hyspin AWH-M 46
• Elf Elfolna HMD 46
• Esso HLPD oil 46
• Mobile hydraulic oil HLPD 46
• Shell Tellus OIL DO 46
Note
Hydraulic oils from other manufacturers can also be used if it can
be demonstrated that they are of the same quality (specifications
according to DIN 51524).
Oil quantity TruBend 3066 TruBend 3120 TruBend 3180

Oil quantity [l] 100 200 250
Tab. 2-7
2-12 4BOperating material - Version 3 B561EN02.DOC

5. Transport
5.1 Customer preparations for

transporting the machine to the
installation site
The customer must make the necessary arrangements and move

the system from the truck to its final installation site.
Clarify the exact route of transportation of the machine to the

installation site well in advance of the delivery of the machine.
Check the following when doing so:
• Gateway openings.
• Header heights.
• Cable rack heights.
• Whether the floor can come into contact with armored rollers.
• etc.
Take into account the dimensions of the machine in accordance

with the installation plan during transport.
Dimensions of the machines TruBend 3066 3120 3180

Length [mm] 2600 3600 4610
Width [mm] 1750 1750 2000
Height [mm] 2330 2330 2330
Tab. 2-8
Preparing auxiliary tools
Additional equipment, tools, material

• Crane truck for unloading truck (loading capacity must be
sufficient to support the weight of the machine, see page 2-5).
• Gantry crane for transporting the machines (carrying capacity:
in accordance with the weight of the machine, see section 1.3,
p. 2-5).
or
Armored rollers (min. carrying capacity 10 t each).
– 1 steerable.
– 2 fixed.
• At least 2 hydraulic hoisting jacks (min. carrying capacity 8 t
each, clearance height <30 mm).
• Hoisting iron with extension.

5.2 Unloading the machine, transporting it
to the installation site
The center of gravity of the machine is very far from the

front.
The machine can easily tip over.
Warning ¾ Use suspension holes for transport and the installation of the
machine.
Checking the damage in transit
1. Check all machine parts for damage in transit after the

delivery.
2. Record any visible damage in transit on the cargo note and
have it countersigned by the truck driver.
3. Report any hidden damage in transit to the insurance company
and to TRUMPF within 6 days.
2-14 5BTransport - Version 3 B561EN02.DOC

Unloading and transporting the machine

• Form A (DIN 82101) shackles.
Use two Form A (DIN 82101) shackles per machine:
Form and dimensions of shackle Fig. 52814
TruBend 3066/3120 3180

Permissible loading [kN] 120 160
Bolt diameter ["] 2 2.4
Main dimensions d1 [mm] 47 52
d4 [mm] 52 60
h1 [mm] 158 185
b1 [mm] 73 81
Tab. 2-9

The machine is equipped with two suspension holes by means of
which the machines can be raised and transported.
D diameter of the suspension x distance of the suspension holes

holes to the upper edge of the
machine
Location of suspension holes Fig. 52190
TruBend 3066 3120 3180

Diameter D [mm] 60 60 70
Distance x to the [mm] 100 100 105
upper edge of the
machine
Thickness of the [mm] 40 60 70
side plate
Tab. 2-10
1. Remove the machine packaging.

2. Fasten shackles to the load suspension points of the machine.
3 Unload machine using a crane.
4 Remove transport protection devices.
5. Transport the accessory cartons included in the delivery as
well as separately packed accessory components directly from
the truck to the installation site of the machine using a fork lift.
6. To transport the machine to the installation site:
¾ Transport the machine on armored rollers.
or
¾ Transport machine using a gantry crane with sufficient
carrying capacity.
2-16 5BTransport - Version 3 B561EN02.DOC

30 31 6. Planning aid
The planning aid provides an overview of the measures to be taken

and the preparations to be made by the customer. For details, refer
to the corresponding chapters of the installation conditions.
Time before delivery of the Planning criteria Measures

machine
8 weeks Personnel and training Appoint a member of staff to be responsible for
course preparations for the delivery of the machine.
Select operating personnel, maintenance personnel,
and programmers. Set dates for training courses.
8 weeks Installation site Determine the machine location. Allow for space
requirements as specified in the installation plan.
Check the floor requirements (floor quality, even-
ness). Observe the weight and dimensions of the
20 machine here.
Check the ambient conditions (room temperature,
exposure to sunlight, ambient air purity).
Check the transport route (gateway dimensions,
header heights, cable rack heights, room to
maneuver around corners etc.).
8 weeks Electric power supply Install the electrical connections at the installation
site.
Conductor cross-sections and fuses according to
legal requirements.
6 weeks Bending tools Order the initial bending tool equipment.

Support from TRUMPF functional department.
4 weeks Operating material Stock up on operating materials
3 weeks Transport Prepare necessary transport aids.
2-3 weeks Feedback Feedback to the TRUMPF department that the

installation conditions have been fulfilled.
During installation and start-up Allocate qualified Establish electrical connections to the system.
electricians
Tab. 2-11

2-18 6BPlanning aid - Version 3 B561EN02.DOC
Chapter 3
Description
1. Machine concept............................................................ 3-3
2. Technical specifications ............................................... 3-4

2.1 Machines.......................................................................... 3-4
2.2 Backgauges ..................................................................... 3-6
2.3 Machine axes................................................................... 3-7
3. The most important modules ....................................... 3-8

3.1 Machine body .................................................................. 3-9
3.2 Upper drive and hydraulic system ................................... 3-9
3.3 Beam................................................................................ 3-9
3.4 Crowning........................................................................ 3-10
Crowning slots with crowning blocks ........................ 3-10
Mechanical crowning ................................................ 3-11
Hydraulic crowning ................................................... 3-11
3.5 Control panel ................................................................. 3-12
T3000 VA control system ......................................... 3-13
3.6 Foot switch..................................................................... 3-15
3.7 Backgauge..................................................................... 3-16
2-axes backguage .................................................... 3-17
B561EN03.DOC 0BDescription 3-1

3.8 Tool clamping ................................................................ 3-18
Manual tool clamping................................................ 3-19
TRUMPF Quick Clamp for upper tools (optional)..... 3-20
Pneumatic tool clamping (optional) .......................... 3-21
3.9 Standard support bracket .............................................. 3-21
4. Tools ............................................................................. 3-22

4.1 Tools from TRUMPF...................................................... 3-22
4.2 Programming the tools................................................... 3-23
5. The most important options ....................................... 3-24

5.1 Additional foot switch ..................................................... 3-24
5.2 Manual operator console ............................................... 3-25
5.3 Network connection ....................................................... 3-26
Functions of the magnetic plate................................ 3-29
Indicator lamp on the transmitter .............................. 3-30
Safety notes.............................................................. 3-30
5.5 Light curtain ................................................................... 3-31
3-2 0BDescription B561EN03.DOC

1. Machine concept
The TruBend Series 3000 contains CNC-controlled, hydraulic

press brakes for bending plane metal sheets by forming.
The machines offer solutions to various bending problems and are

characterized by the following features:
• CNC backgauge system.
• Four-cylinder upper drive.
• Fast and easy operation and programming.
• High degree of occupational safety.
• Defined inclined position of the beam.
B561EN03.DOC 1BMachine concept 3-3

2. Technical specifications
2.1 Machines
TruBend 3066 3120 3180

Services Press force [kN] 660 1200 1800
Length of bend [mm] 2080 3110 4140
Machine Weight [kg] 4900 7700 13200
measurements
Length [mm] 2600 3600 4610
Width [mm] 1750 1750 1800
Height [mm] 2330 2330 2330
Width between columns [mm] 1750 2690 3680
Throat [mm] 420 420 420
Work table width [mm] 80 100 150
Working height Installation height [mm] 470 470 470
Tool installation height (TRUMPF) [mm] 347 347 347
Working height with lower tool [mm] 1000 1000 1000
100 mm
Y axis speeds Y rapid speed [mm/s] 200 115 200
Y working speed With CE [mm/s] 10 10 10
Without [mm/s] 20 12 15
CE
Y spindle return speed [mm/s] 180 135 180
Y axis (beam) Version - CNC- CNC- CNC-controlled
controlled controlled
Stroke [mm] 200 200 200
Positioning accuracy [mm] ±0.01 ±0.01 ±0.01
Inclined position [mm] ±3.0 ±3.0 ±3.0
Max. stop range X [mm] 880 880 880
Connected loads Electric [kW] 11 11 18.5
Quantity of hydraulic oil [l] 100 200 250
Tab. 3-1
3-4 2BTechnical specifications B561EN03.DOC

Installation height: 470 mm
Throat: 432 mm
Tool installation height: 347 mm
Fig. 52431
B561EN03.DOC 2BTechnical specifications 3-5

2.2 Backgauges
The following backgauge systems are possible:

• 2-axis backgauge.
• 4-axis backgauge (optional).
• 5-axis backguage (optional): 4-axes backgauge with an addi-
tional gauge finger (X5 axis).
TruBend Series 3000

X axis Version CNC-controlled
Traverse path [mm] 600
Positioning accuracy [mm] 0.05
Travel speed [mm/s] 500
X5 axis Version CNC-controlled
(optional)
Travel speed [mm/s] 500
R axis Version CNC-controlled
Travel speed [mm] 200
Z axis Version Manual or CNC-controlled
Tab. 3-2
3-6 2BTechnical specifications B561EN03.DOC

2.3 Machine axes
Fig. 52440
Axis Description TruBend Series 3000

R axis Gauge finger height adjustment CNC-controlled
X axis Backgauge traverse path forwards CNC-controlled
and backwards
Y axis Stroke and inclined position of the CNC-controlled
beam
Z axis Left and right gauge finger Manual or CNC-
displacement controlled
Tab. 3-3
B561EN03.DOC 2BTechnical specifications 3-7

3. The most important modules
2
6
7
3
8
4
10
1 Upper drive 5 Press beam 9 Crowning

2 Control system 6 Upper tool holder 10 Machine frame
3 Switch cabinet (left-hand side) 7 Backgauge
4 Support brackets 8 Lower tool holder
Fig. 52441
3-8 3BThe most important modules B561EN03.DOC

3.1 Machine body
The FEM-designed machine body is an all-steel welded

construction. It consists of two side elements, the press table and a
connection support. The machine frame is particularly
distinguished by:
• Consistently high level of accuracy.
• Large throat for a large bending space.
• Easy access to the tool holder.
3.2 Upper drive and hydraulic system
The beam is driven by a high-pressure internal gear pump via a

self-ventilating proportional path hydraulic system. An integrated
path measurement system which is in constant communication
with the control system provides machine frame springback com-
pensation, thereby guaranteeing the correct positioning of the
beam during press brake bending.
This combination has the following advantages:
• The press force is immediately available.
• A high level of positioning accuracy allows for the precise
reproduction of bending angles, even for large-scale jobs.
• The machine is particularly quiet.
Inclined position of the beam Both hydraulic cylinder pairs on each side can be triggered
separately. This allows a defined inclined position of the beam to
be programmed.
3.3 Beam
The beam is suspended spherically in the machine frame. Its main

features include:
• Consistently high level of accuracy.
• High level of bending rigidity.
B561EN03.DOC 3BThe most important modules 3-9

3.4 Crowning
Crowning compensates for the bowing of the beam and press table
in order to achieve a consistent and straight bend along the entire
length.
The following types of crowning are possible:

• Crowning shots with crowning blocks.
• Mechanical crowning (for TruBend 3120).
• Hydraulic crowning (for TruBend 3180).
Crowning slots with crowning blocks
The crowning setting is automatic: there are two crowning slots

located on both sides of the press table which cause the press
table to apply more force on the outer sides than in the middle
position, thus adjusting perfectly to the bowing of the beam.
1 1
1 Crowning slots
Press table with crowning slots Fig. 29748
The press table and crowning slots have been designed so that the
correct crowning is always applied.
The crowning can be activated as well as deactivated using a
lever.
Fig. 52436

Mechanical crowning
In addition to standard crowning, the TruBend 3120 is also

equipped with mechanical crowning that is at the center of the
press table.
The press table (from a width of 3 m) is raised with the help of a
wedge system. A uniform angle can be ensured for longer bends
as well.
Hydraulic crowning
In addition to standard crowning, the TruBend 3180 is also

equipped with hydraulic crowning that is at the center of the press
table. A uniform angle can be ensured for longer bends as well.
The press table (from a width of 4 m) is raised with the help of a
hydraulic cylinder. The hydraulic cylinders (flat cylinders) are
installed in a slotting in the machine frame.
The crowning value is calculated and displayed by the control
system. The value can be manually adapted if required.
1 2 1
1 Crowning slot with wedge 2 Hydraulic crowning

system
Fig. 52442

3.5 Control panel
The machine is normally equipped with a graphical control system

T3000 VA.
CNC programs can be programmed directly or generated and
stored using graphically produced product drawings.
2
3 7
4 8
5
9
6 10
11
12
1 LCD display/screen 7 END

2 Softkeys S1 to S8 8 Cursor keys
3 HELP 9 Jog button
4 EMERGENCY STOP impact 10 Operating mode keys
button 11 START
5 Alphanumeric keyboard with 12 STOP
ENTER
6 Touch Pad
Operating elements on the control panel Fig. 52434

T3000 VA control system
Help, wherever it is required Help texts for individual parameters are stored in the control
system; these can be called up via HELP.
The following operating modes are possible:

• Manual operation.
• Programming mode.
• Automatic mode (production).
• Step-by-step operation.
Programming The following programs can be programmed at the control system:

• Single bending (manual operation).
• Bending program with several bends (programming operation):
– Numerical programming.
– Graphical programming (2D).
Production The following bending programs can be produced in the automatic

mode:
• Numerical bending programs programmed at the control
system.
• Interlinked programs.
• Graphical programs programmed at the control system (2D).
• Programs programmed in TruTops Bend.
Step-by-step operation Every bend is individually processed in the step-by-step operation.

Every bend must be restarted using START.

Technical specification for T3000 VA
the control system
Screen 10.4" TFT LCD, color
Number of controllable axes 30
Memory capacity >40 MB,
198 tools
Program number 7-digit
Bending time computation yes
Bending sequence computation yes
3D visualization (optional) yes
Press force computation yes
Effective length computation yes
Bending radius computation yes
Number of step repetitions max. 99
Automatic crowning function yes
Number of workpieces preselection yes
Interface RJ45
Data backup Flash memory stick
USB 2
Tab. 3-4

3.6 Foot switch
The movement of the beam is triggered using the foot switch. It is

ergonomic and user-friendly and consists of an indicator lamp and
three buttons:
• EMERGENCY STOP impact button on the upper side.
• BEAM DOWN foot switch with EMERGENCY STOP function.
• EMERGENCY-UP foot switch.
1 EMERGENCY STOP impact 3 EMERGENCY-UP foot switch

button 4 BEAM DOWN foot switch
2 Indicator lamp
Foot switch Fig. 52437

3.7 Backgauge
The backgauge supports the workpiece during bending.
The following backgauge systems are possible:

• 2-axis backgauge.
• 4-axis backgauge (optional).
• 5-axis backguage (optional): 4-axes backgauge with an CNC-
controlled gauge finger (X5 axis).
Upward folding gauge fingers In case of a collision, the ideally hinged standard gauge fingers flip
backwards. This prevents damage to bending parts and to the
gauge finger.
Safe shifting of the gauge The gauge fingers can be moved 20 mm in front of the tool plane
fingers for repositioning. Because of this, the operator does not have to
reach through the tool plane unassisted or using an auxiliary tool.
Backgauge system Fig. 52435

2-axes backguage
The gauge depth (X axis) and the gauge height (R axis) are CNC-
controlled. Improved workpiece quality is achieved by means of
better control performance and RPM accuracy of the digital drive
controllers for these axes.
Additional features of the CNC backgauge system include:

• No tooling times for X and R axes, as the gauge height and
depth can be programmed freely at the control system.
• High positioning speed and wide traverse paths. This also
ensures minimum production time, even for large workpieces.
• Minimal handling time.
• Infinitely variable programming of X and R axes enables the
machining of complicated products and minimizes gauge
tolerances.
4-axes backgauge (optional)
The 4-axis backgauge is an extension of the 2-axis backgauge. In

addition to the CNC-controlled gauge depth (X axis) and gauge
height (R axis), lateral adjustment of the gauge fingers (Z1/Z2
axes) is also CNC-controlled.
The gauge finger position is programmed directly into the control
system, eliminating the need for manual gauge finger adjustment.
5-axes backgauge (optional)
Extended backguage concept The 5-axes backguage with a relative X-axis (X5 axis) is a
configuration stage of the 4-axes backgauge. One of the two
gauge fingers can be moved in the X direction by ±80 mm in an
NC-controlled manner.
The X5 axis can be programmed in the control system.

3.8 Tool clamping
Upper tool holder The upper tool clamp is self-centering. An idle stroke is not re-
quired to align individual upper tool segments after a tool change.
All upper tools can be inserted from both sides. This reduces tool
costs to a great extent, as elbowed tools in particular can be used
in a flexible manner.
Upper tools up to a length of 100 mm are equipped with Safety-
Click® and can be changed vertically.
The following upper tool holders are possible:

• Manual clamping, individual segments:
– For TRUMPF tools (standard).
– For Amada tools (Asia).
– For Amada tools (USA).
– For LVD tools (USA).
• TRUMPF Quick Clamp, individual segments (optional):
• Pneumatic clamping, individual segments (optional).
– For TRUMPF tools.
– For Amada tools (Asia).
– For Amada tools (USA).
• Pneumatic clamping, uniform (optional).
Lower tool holder The lower tool holder is wear-resistant. It is also possible to adjust
the tool holder when using tools from other manufacturers.
The following lower tool holders are possible:

• Manual clamping (standard).
• Pneumatic clamping (optional, possible only for pneumatic
upper tool holder).
In addition to the lower tool holder for TRUMPF tools, adapters for
Amada dies are available.

Manual tool clamping
Upper tool clamping The manual tool clamping consists of individual segments that can
be opened and closed with two hexagonal socket screws.
Fig. 52973
Lower tool holder The manual tool clamping for lower tools consists of individual
segments that can be opened and closed with three hexagonal
socket screws.
Fig. 52974

TRUMPF Quick Clamp for upper tools
(optional)
TRUMPF provides TRUMPF Quick Clamp, a manual quick clamp-

ing for the upper tools of the TruBend Series 3000. Upper tools can
be quickly and effectively clamped using this device. Divided
clamping pieces in the tool holder ensure that even narrow tool
segments are optimally held.
Clamping power is infinitely The required clamping power for the upper tools is infinitely
adjustable adjustable manually.
Fig. 52439

Pneumatic tool clamping (optional)
The pneumatic tool clamping always contains the clamping for

upper and lower tools.
The pneumatic upper tool holder (individual segments) is
available for:
• TRUMPF tools.
• Amada tools (Asia).
• Amada tools (USA).
The uniform pneumatic upper tool holder is available for:

• TRUMPF tools.
TRUMPF pneumatic tool clamping (uniform) Fig. 50411
Note
The terminal strips can be removed in order to use Amada tools.
3.9 Standard support bracket
The support brackets support the operator when processing heavy

and unwieldy workpieces. The support console must be used when
using foot switch.
The console system consists of two consoles.
Properties of the support bracket:

• Easy to operate.
• Height adjustable.
• Demountable
• Linearly movable.

4. Tools
4.1 Tools from TRUMPF
Terminology
2
6
3
4
7
1 Upper tool (punch) 5 Die width

2 Workpiece 6 Lower tool radius
3 Inner workpiece radius 7 Upper tool radius
4 Outer workpiece radius 8 Lower tool (die)
Tools and workpiece Fig. 12763
All tools and special tools by TRUMPF that can be used for the
TruBend Series 3000 have already been stored in the control
system.
The entire range of available tools is compiled in a catalog and
items can be ordered from it.
3-22 4BTools B561EN03.DOC

TRUMPF bending tools The work surfaces for all tools and the support areas of the lower
LASERdur® tool holders are hardened. The work radii of all tools are laser-
hardened. This has the following advantages:
• Long service life of the tools.
• High levels of machine accuracy maintained over time.
Tools of varying lengths All tools exist in various graduations and lengths that can be
combined with one another:
• Several tool stations can be used.
• Lower tool costs.
• Time-efficient operation.
Safety-Click safety element® All tools with a length of up to 100 mm are equipped with Safety-
Click®. This safety device prevents the tools from falling out of the
tool clamping. The lock can be released by pushing a button:
• The upper tools can be changed quickly and safely in vertical
position.
• Shorter tool set-up times because tools must no longer be
removed laterally from the upper tool holder.
Using for folding over TRUMPF upper tools can be inserted on both sides. This results in
a considerable reduction of tool costs particularly with elbowed
tools.
Self-centering The upper tool holder for TRUMPF tools is self-centering. Upper
tools do not have to be aligned by means of an idle stroke before
the first bending.
4.2 Programming the tools
All tools and special tools from TRUMPF that can be used for the
TruBend Series 3000 have already been stored in the control
system.
Upper and lower tools which are not yet contained in the control
system (e.g. special tools, tools from other manufacturers) can be
programmed directly into the control system.
B561EN03.DOC 4BTools 3-23

5. The most important options
Tool clamping TRUMPF Quick Clamp (for upper tools)

Pneumatic tool clamping
Backgauge 4-axes backgauge
5-axes backgauge
Additional foot switch
Manual operator console
Network connection
TRUMPF BendGuard
Light curtain
Tab. 3-5
5.1 Additional foot switch
Two operators can work at the machine if an additional foot switch

is connected.
3-24 5BThe most important options B561EN03.DOC

5.2 Manual operator console
The manual operator console consists of the following operating

elements:
• BEAM DOWN (2x) manual button.
• EMERGENCY STOP impact button.
• BEAM DOWN foot switch.
• EMERGENCY-UP foot switch.
1 Indicator lamp 4 BEAM DOWN foot switch

button
3 Manual button
Fig. 52438
Information
• The manual operator console down is active if the indicator
light lights up.
• The EMERGENCY STOP impact button and the
EMERGENCY-UP foot switch are always active.
B561EN03.DOC 5BThe most important options 3-25

Two-hand operation Manual buttons and foot switch BEAM DOWN are active. Both the
operating mode manual buttons must be pressed at the same time to move the
beam (with rapid speed up to the mute point). From the mute point,
the BEAM DOWN foot switch also needs to be pressed to move
the beam at the operating speed (max. 10 mm/s).
5.3 Network connection
Programs, tools and machine parameters can be directly imported

to the control system from a network drive or saved from the
control system onto a network drive.
Unlimited size of the The advantages are obvious:

memory capacity • Memory capacity for the bending programs can be expanded
as required.
• Backup by the external data memory prevents data loss.
Data can still be managed using diskettes, as before.
5.4 TRUMPF BendGuard
Note
Working at a rapid speed >10 mm/s is permitted only when an
optoelectronic safety device is used.
Innovative safety concept TRUMPF BendGuard enables work at rapid speed without impair-
ing the safety of the operating personnel. The area below the up-
per tool is thus monitored constantly by two moving bands of three
visible red laser beams. If the light beams are interrupted, the
downward movement of the beam is stopped.
TRUMPF BendGuard is a non-contact protection device (BWS) of

type 4 according to EN 954 with integrated springback verification
device.A safety level in accordance with EN 12622 (2001) 5.3.2(f)
has been achieved.

Principle Three parallel laser beams shine in front of the upper tool at a
distance of 4 mm (laser light A) and 14 mm (laser light B) under the
upper tool tip and serve as hand and finger protection. The
effective width of the laser band starts 20 mm in front of and ends
20 mm behind the upper tool tip.
Note
Laser light A is only visible when the foot switch is pressed.
1 2 3 4 5 6
1 Transmitter 4 Lower tool

2 Laser light A 5 Upper tool
3 Laser light B 6 Receiver
Principle of the TRUMPF BendGuard Fig. 30830
The 40 mm wide laser lights are divided into three individual

beams:
• An approximately 20 mm wide laser light in front of the upper
tool tip.
• A laser beam with circular cross-section under the upper tool
tip.
• An approximately 20 mm wide laser light behind the upper tool
tip.
In this way BendGuard knows if the light interruption should be

before, exactly under or behind the upper tool tip. If the laser light
is interrupted, the beam is stopped.
The upper tool can be moved at rapid speed up to the mute point
(switch-over point from rapid speed to working speed), after which
the bending process takes place at working speed.
When bending boxes or troughs, the two outer laser beams can be
deactivated (nesting mode). This avoids collision contours through
side walls that have already been bent. Operator safety is ensured
by the middle beam.

If the laser beams hit an obstacle, the machine stops. When the
obstacle is removed, the bending procedure can be continued by
pressing the foot switch again. This ensures 100% hand and finger
protection in the area of the outward laser beam.
1 Laser lights A and B 3 Mute point

2 Obstacle 4 Workpiece
Fig. 31069
Advantages • Rapid speed is permissible only with foot operation; the hands
remain free for handling the tools.
• Optimal productivity; no reduction in cycle time compared to
operation without this safety application.
• Choice between normal mode with three beams and nesting
mode with one or two beams.
• Intermediate storage in the provided holding fixture in the direct
vicinity of the place of use.
• Quickly adjustable to all standard tool heights.
• User friendly, because the programming functions and displays
are integrated into the standard control system.
• Programming errors during the determination of the mute point
are monitored and cause no safety risk.
Further functions In addition to light beam interruption, TRUMPF BendGuard also

monitors the speed of the beam at rapid speed and working speed,
the springback of the beam and the position of the mute point.
Fastening to the machine TRUMPF BendGuard is laterally mounted on the beam and can
thus be easily moved upwards for replacing an upper tool.

Functions of the magnetic plate
This magnetic plate is magnetic. There is a functional area on the

black rear side:
• Millimeter scale from 0 to 20 mm.
Magnetic plate Fig. 35733
Position of the laser beam The magnetic plate is used to check the position of the laser beam
under the upper tools. To do this, the millimeter scale is printed on
the magnetic plate.
Further functions The following points are only necessary for a sheet thickness
<1 mm or die widths ≥40 mm. Magnetic plates are not required in
all other cases:
• Simulation of the sheet thickness:
– The magnetic plate is slid upwards by the thickness of the
sheet when the mute point is being determined. To do this,
the millimeter scale is printed on the magnetic plate.
• Shielding the laser beam after the mute point:
– TRUMPF BendGuard requires and monitors the correct
definition of the mute point. The laser beam must be
interrupted after reaching the mute point. Otherwise, the
bending cycle is not completed.
– This interruption is caused by placing the magnetic plate
on the lower tool laterally. This hinders the laser beam
from shining through the lower tool.

Indicator lamp on the transmitter
A red indicator lamp is located on the BendGuard transmitting unit:

• Lit up continuously: the indicator lamp is lit up continuously
once the mute point has been reached or when the laser beam
is interrupted.
• Slow blinking: In the nest bending mode (BendGuard modes 2
and 4) the indicator lamp blinks slowly until the mute point has
been reached or until the laser beam has been interrupted.
• Rapid flashing: the indicator lamp flashes rapidly in the event
of malfunctions or screen messages.
Safety notes
Risk of injury!
Do not touch live parts.
¾ Do not open any of the TRUMPF BendGuard parts.
Warning
Class 1 laser light!

Risk of injury to the eyes.
¾ Never look directly into the laser.
Warning
¾ The laser light is harmless to the body surface.
Safety after the mute point TRUMPF BendGuard requires and monitors the correct definition
of the mute point. The laser beam must be interrupted after
reaching the mute point. Otherwise, the bending cycle is not
completed.
This interruption is caused by placing the magnetic plate on the
lower tool laterally. This hinders the laser beam from shining
through the lower tool during the bending cycle.
From the mute point on, it can not differentiate between loading
your finger or a metal sheet, as the laser beam is switched to mute
mode. But if the mute point has been correctly defined, it should
not be possible to jam your finger in the narrow gap between upper
tool and the lower tool.

Checking the function before An inspection must be carried out every day to determine whether
starting work TRUMPF BendGuard is working perfectly. Do not trust the setting
without first checking yourself.
1. Interrupt the laser beam with an object during the closing

motion in rapid speed.
The downward motion of the beam must come to a stop.
2. Check the mute point.
Avoiding contamination ¾ Keep the transmitter and receiver panes free of dust, dirt, and
oil.
¾ Avoid scratches in the beam area.
¾ Clean the window only with a soft, slightly damp cotton cloth.
5.5 Light curtain
Note
Optimum protection without The light curtain is an optoelectronic safety device for the operator
loss of productivity and enables operation of the machine at rapid speed (220 mm/s).
The light curtain is attached in front of the beam and press table
and protects against obstacles from a length of 14 mm.
If the light curtain is interrupted, the beam stops and moves to the
upper dead point in order to avoid injuries.

Chapter 4
Operation
1. Description of the operating elements ........................ 4-3
1.1 Foot switch....................................................................... 4-3
1.2 Manual operator console (optional) ................................. 4-4
1.3 Operating elements at the switch cabinet........................ 4-5
1.4 Operating elements for the control system...................... 4-8
1.5 User interface structure ................................................. 4-10
Programming mode .................................................. 4-10
1.6 Operating modes ........................................................... 4-10
Selecting or activating operating modes .................. 4-11
2. Switching on the machine .......................................... 4-12

2.1 Enabling EMERGENCY STOP...................................... 4-12
2.2 Switching on the machine.............................................. 4-13
3. Switching off the machine .......................................... 4-14

3.1 Switching off the machine in case of emergency or
malfunction .................................................................... 4-14
3.2 Switching off the machine.............................................. 4-14
4. Using Online help ........................................................ 4-15
B561EN04.DOC 0BOperation 4-1

5. Entering letters ............................................................ 4-15

6.1 Safety mode................................................................... 4-16
BendGuard mode ..................................................... 4-16
Light curtain mode .................................................... 4-18
6.2 Selecting the safety mode ............................................. 4-19
6.3 Operating the machine without optoelectronic
safety device.................................................................. 4-19
7. Loading a program ...................................................... 4-20
8. Creating a program...................................................... 4-21

8.1 Creating a program manually ........................................ 4-21
8.2 Interlinking two programs............................................... 4-22
(drawing profile) ............................................................. 4-23
9. Modifying the program................................................ 4-26
10. Programming individual bends.................................. 4-26
11. Creating a tool.............................................................. 4-27
12. Program Management ................................................. 4-29
13. Tool data management................................................ 4-31
14. Changing the language ............................................... 4-33
15. Setting the program data ............................................ 4-33
16. Switching between MSC and ASV ............................. 4-34

16.1 Switching from ASV to MSC .......................................... 4-35
16.2 Switching from MSC to ASV .......................................... 4-35
16.3 Programming step change............................................. 4-36
17. Bending workpieces.................................................... 4-37
18. Bending workpieces step by step.............................. 4-38
19. Moving axes manually................................................. 4-39
4-2 0BOperation B561EN04.DOC

1. Description of the operating elements
1.1 Foot switch
The movement of the beam is triggered via the BEAM DOWN foot
switch.
The indicator lamp shows whether the foot switch is active.

button 4 BEAM DOWN foot switch
2 Indicator lamp
Foot switch Fig. 52437
B561EN04.DOC 1BDescription of the operating elements 4-3

1.2 Manual operator console (optional)
The movement of the beam is triggered using the manual button or

the BEAM DOWN foot switch.
The indicator lamp shows whether the manual operator console is
active.
1 Indicator lamp 4 BEAM DOWN foot switch

button
3 Manual button
Fig. 52438
4-4 1BDescription of the operating elements B561EN04.DOC

1.3 Operating elements at the switch
cabinet
2 5
1 HYDRAULIC SYSTEM ON 4 MAIN SWITCH

2 HYDRAULIC SYSTEM OFF 5 Light on/off (optional)
3 Key switch (Operating mode
selection)
Operating elements at the switch cabinet Fig. 52980

1 HYDRAULIC SYSTEM ON 4 HYDRAULIC SYSTEM OFF
2 Key switch (operating mode 5 Light on/off (optional)
selection) 6 Service switch
3 MAIN SWITCH 7 EMERGENCY STOP impact
button
Operating elements at the switch cabinet (USA) Fig. 52443

Operating elements Description
Switching off the hydraulic system.
Switching on hydraulic system.
Key switch (operating No operating mode selected.

mode selection)
Setup mode:
• Moving the machine axes manually (using the JOG buttons at the control
system).
Foot operation:
• Operating the machine in foot operation (an operator, a foot switch active).
• Trigger the stroke via the BEAM DOWN foot switch.
Two-foot operation (optional):

• Operate the machine with two foot switches (two operators, two foot
switches active).
• Trigger the stroke via the BEAM DOWN foot switch.
key switch options ROBOT Robot operation (optional):

(operating mode • Operate the machine with a robot or without an optoelectronic safety
selection options) device.
Protect mode operating mode (optional):
• Machine with robot: Switch off the robot and activate the optoelectronic
! safety device (BendGuard or light curtain).
Two-hand operation (optional for machine without CE marking):
• Operate the machine using the manual operator console (one operator,
a manual operator console active).
• Trigger the stroke via the manual operator console.
Four-hand operation (optional for machine without CE marking):

• Operate the machine with two manual operator consoles (two operators,
two manual operator consoles active).
• Trigger the stroke using the both the manual operator consoles.
Tab. 4-1
Note
The operating mode of the machine is selected using the key
switch and the appropriate parameters at the control system (see
section 1.6, p. 4-10).

1.4 Operating elements for the control
system
2
3 7
4 8
5
9
6 10
11
12
1 LCD display/screen 7 END

2 Softkeys S1 to S8 8 Cursor keys
3 HELP 9 JOG button
4 EMERGENCY STOP impact 10 Operating mode keys
button 11 START
5 Alphanumeric keyboard with 12 STOP
ENTER and RESET
6 Touch Pad
Operating elements on the control panel Fig. 52434

Operating mode keys
Symbol Name Description
MANUAL OPERATION Program individual bends.
Execute individual bends.
PROGRAMMING MODE Create and edit programs.

Save and load programs
AUTOMATIC MODE Process programs .
STEP-BY-STEP Execute every bend of a

OPERATION program individually.
Tab. 4-2

1.5 User interface structure
Programming mode
Function/Main operation Description

1. Product input Create a program graphically (2D).
2. Product editing Modify a graphical program (2D).
3. Program input Create a program.
4. Program editing Modify a program.
5. Product overview Displaying and loading programs stored in the
machine directory.
6. Save product Loading or saving bending programs (saving
on a data carrier).
7. Upper tools Creating and modifying tools.
Assigning tools with tool numbers.
8. Lower tools
9. Beam Display the machine dimensions.
10. Press table
11. Program data Configure general settings (e.g. change the
language).
12. Save tools Loading or saving tool data (saving on a data
carrier).
Tab. 4-3
1.6 Operating modes
The following operating modes are possible:

• Foot mode.
• Two-foot mode (optional).
• Two-hand operation (optional for machine without CE
marking).
• Four-hand operation (optional for machine without CE
marking).

Selecting or activating operating modes
1. Select MANUAL OPERATION or PROGRAMMING MODE.

2. Enter the desired parameters.
Note
If only one foot switch is connected, the "FD on/off" or "2 FD
on/off" parameters are not displayed.
3. Under "FD on/off" or "2 FD on/off", select the desired foot
switch or manual operator console.
Parameters Value
"FD on/off" Setting for activating the foot switch or the manual operator
console:
• 0 = Foot switch 1 is active (only one foot switch or one
manual operator console is connected).
• 1 = Two foot switches or manual operator consoles are
active.
"2 FD on/off" Displays if one or two manual operator consoles are
connected.
Settings for the manual operator console:
• 00 or 01 = Foot operation (only the foot buttons of the
manual operator console are active).
• 10 = Two-hand or foot operation (foot button and manual
button are active. Both the manual button and the foot
button BEAM DOWN must be pressed simultaneously.).
• 11 = Two-hand operation (both the manual button must
be pressed simultaneously).
Tab. 4-4
4. Press ENTER.
5. Setting the key switch for selection of operating modes at the
switch cabinet to the desired operating mode (see section 1.4,
p. 4-8).
Examples:
"FD on/off" = 1 Two manual operator consoles are active but
"2 FD on/off" = 00 (or 01) only the foot button is used.
"FD on/off" = 1 Two foot switches are connected and active.

"2 FD on/off" is not displayed
Tab. 4-5

2. Switching on the machine
2.1 Enabling EMERGENCY STOP
EMERGENCY STOP functions can be found at the following

locations:
• EMERGENCY STOP impact button at the control system.
• MAIN SWITCH with EMERGENCY STOP function.
• Foot switch with EMERGENCY STOP impact button.
• Manual operator console with EMERGENCY STOP impact
button.
Prerequisite
• The lateral and rear safety doors on the machine are closed.
• The door of the switch cabinet is closed.
Enabling EMERGENCY STOP ¾ Turn the impact button to the right and pull it out.
at the control system
Enabling EMERGENCY STOP ¾ Turn the MAIN SWITCH to ON.

via the MAIN SWITCH
Enabling the EMERGENCY ¾ Turn the impact button to the right and pull it out.
STOP at the foot switch
or
¾ Press the EMERGENCY-UP foot button.
4-12 2BSwitching on the machine B561EN04.DOC

2.2 Switching on the machine
Prerequisite
• The door of the switch cabinet is closed.
• EMERGENCY STOP enables.
• The lateral and rear safety doors on the machine are closed.
Collision in case of set up high tools (from a tool height of

220 mm) possible!
¾ Remove upper and lower tools completely.
Caution
Backgauge fingers may collide with loaded tools!

¾ Loaded tools need to match with the currently programmed
positions of the X and R axes.
Caution
1. Switch on the MAIN SWITCH on switch cabinet.

The machine control system will start up.
The Failsafe safety check is complete after approx 30 s. The
indicator lamp on the foot switch lights up.
2. Press MANUAL MODE.
3. Press the EMERGENCY-UP foot button.
Beam will move to the upper dead point.
4. Press START on the control system.
All axes with the exception of the Y1/Y2 axis are automatically
referenced.
Note
The traverse path for the springback test of the beam is
50 mm. The tools must be loaded such that this traverse path
is possible.
5. Press the BEAM DOWN foot switch.
The springback test is carried out.
The BendGuard reference travel is carried out.
B561EN04.DOC 2BSwitching on the machine 4-13

3. Switching off the machine
3.1 Switching off the machine in case of

emergency or malfunction
¾ Press the EMERGENCY STOP impact button on the foot

switch.
or
¾ Press EMERGENCY STOP on the control system.
or
¾ Turn the MAIN SWITCH on the control cabinet to O.
or
¾ Push the BEAM DOWN foot switch down hard (EMERGENCY
STOP function of the foot switch is triggered by pressing the
foot switch with a force of between 220 N and 350 N).
Note
If the hydraulic system is switched off via EMERGENCY STOP, it
can be switched on again using the EMERGENCY-UP foot switch.
3.2 Switching off the machine
1. Place a protective workpiece between tools.

2. Lower the beam until there is a gap of approx. 7 mm between
the upper tool tip and the surface of the inserted workpiece.
3. Press HYDRAULIC SYSTEM OFF on the switch cabinet.
The hydraulic system will be switched off and all machine
activities stopped.
4. Turn the MAIN SWITCH to 0.
4-14 3BSwitching off the machine B561EN04.DOC

4. Using Online help
Online help for operating the control system can be displayed on

the control system of the machine. If a question mark (?) is
displayed at the control systems, help texts are saved.
1. Press ?.
The help text is displayed.
2. Display the previous or the next page of the help using
Previous page (S2) or Next page (S3).
3. Close the help text using End (S7).
5. Entering letters
The control system has one alphanumeric keyboard. Numbers and

letters are given on every key. If letters can also be entered apart
from numbers, the alphanum softkey is active.
Letters can be entered for:

• Drawing numbers.
• Tools names.
• Directory/folder names.
1. Press the key having the desired letter.

The number of the key is displayed.
2. Press alphanum (S6) till the desired letter is displayed.
Example:
1. Press the 4 key.

4 is displayed.
2. Press alphanum (S6).
G is displayed.
3. Press alphanum (S6).
H is displayed.
B561EN04.DOC 4BUsing Online help 4-15

6. Optoelectronic safety devices
The machine can be equipped with TRUMPF BendGuard or a light

curtain.
Note
6.1 Safety mode
BendGuard mode
Mode Description
0 "Normal mode" Profile mode:
All three laser beams are active.
¾ Press the BEAM DOWN foot switch.

The beam moves up to the mute point at rapid
speed and then moves further at operating speed
(max. 10 mm/s) automatically.
The beam stops if the laser beam is interrupted during

the rapid traverse.
1 "Specialist Nesting mode:
mode" Only the middle laser beam is active.
In the nesting mode, the nesting height (interruption
height) must be specified.

speed and then moves further at working speed

the rapid traverse.
2 "Transit mode Operation without optoelectronic safety device:
field" The safety device is switched off (BendGuard or the light
curtain).
The beam moves at a maximum speed of 10 mm/s
(operating speed).

4-16 6BOptoelectronic safety devices B561EN04.DOC

Mode Description
3 "Normal mode, Profile mode with stop at the mute point:
stop at the All three laser beams are active.
transition
point" 1. Press the BEAM DOWN foot switch.
The beam moves to the mute point and stops.
The beam moves at operating speed
(max. 10 mm/s).

the rapid traverse.
4 "Specialist Nesting mode with stop at the mute point:
mode, stop at Only the middle laser beam is active.
the transition
point" In the nesting mode, the nesting height (interruption
height) must be specified.


the rapid traverse.
5 "Transit mode Operation without optoelectronic safety device with
field, stop at stop at the mute point:
transition The safety device is switched off (BendGuard or the light
point" curtain).
(operating speed).
(max. 10 mm/s).
Tab. 4-6
B561EN04.DOC 6BOptoelectronic safety devices 4-17

Light curtain mode
Mode Description
2 "Transit mode Operation without optoelectronic safety device:
field" The safety device is switched off (BendGuard or the light
curtain).
(operating speed).

5 "Transit mode Operation without optoelectronic safety device with

field, stop at stop at the mute point:
transition The safety device is switched off (BendGuard or the light
point" curtain).
(operating speed).

(max. 10 mm/s).
6 "Only protect Protect mode:

mode" ¾ Press the BEAM DOWN foot switch.
The beam stops if the light field in rapid traverse is

interrupted.
7 "Single One-cycle mode (with stop at the mute point):
interruption 1. Interrupt the light field once and press the BEAM
mode" DOWN foot switch.
The beam moves to the mute point in rapid traverse
and stops.
(max. 10 mm/s).
If the light field with operating speed is interrupted, the

next strole after the bending is automatically started.
8 "Double Two-cycle mode (with stop at the mute point):

interruption 1. Interrupt the light field twice and press the BEAM
mode" DOWN foot switch.
The beam moves to the mute point in rapid traverse
and stops.
(max. 10 mm/s).
If the light field with operating speed is interrupted, the

next strole after the bending is automatically started.

Mode Description
9 "Only protect Protect mode with stop at the mute point:
mode, stop at 1. Press the BEAM DOWN foot switch.
transition
point" The beam moves to the mute point in rapid traverse
and stops.
(max. 10 mm/s).
The beam stops if the light field in rapid traverse is

interrupted.
Tab. 4-7
6.2 Selecting the safety mode

3. Enter or select the desired safety mode under "SM safety
mode".
– BendGuard: 0, 1, 3 or 4 (see section 6.1, p. 4-16).
– Light curtain: 6, 7, 8 or 9 (see section 6.1, p. 4-16).
4. Press ENTER.
6.3 Operating the machine without

optoelectronic safety device
On machines without optoelectronic safety devices, modes 2 nd 5

are provided at the user interface. In this mode, the beam moves at
a safe speed (max. 10 mm/s).

3. Enter or select the desired safety mode under "SM safety
mode".
– 2 or 5 (see section 6.1, p. 4-16).
4. Press ENTER.

7. Loading a program
Programs can be loaded from the bending program directory of the

machine.
Note
Bending programs must be saved in the bending program directory
of the machine so that they can be loaded or processed.
1. Press PROGRAMMING MODE.

2. Select "5. Product overview".
The machine directories are displayed. The last opened
directory is always displayed.
3. To select the directory, select local directory (S7).
4. Select the desired directory using Select (S6).
– "(Parent)": open the next higher directory.
5. To create a new folder: press Create a subdirectory (S4), enter
the name of the directory and press ENTER.
6. To adapt the display of the bending programs: select View
(S4).
SOFTKEY Description
normal directory (S4) Display bending programs in a list.
Dir expand (S5) Display bending programs in a list with details.
graph dir (S6) Display a graphical preview of the bending programs.
Tab. 4-8
7. To search for a bending program: select Filter (S5).
SOFTKEY Description
Prod. No (S5) Search for the product number of a bending program.
Drawing no. (S6) Search for the drawing number of a bending program.
Tab. 4-9
8. Mark the desired bending program and select it using ENTER.

9. Press End.
The bending program is loaded (PROGRAMMING MODE, AUTO-
MATIC MODE and STEP-BY-STEP OPERATION). A message is
displayed.
4-20 7BLoading a program B561EN04.DOC

8. Creating a program
Bending programs can be created at the machine in various ways:

• Creating a program manually.
• Creating a program graphically (drawing a profile).
8.1 Creating a program manually
1. Select PROGRAMMING MODE.

2. Select "3. Program input".
Note
Pay attention to the Online help (see section 4, p. 4-15).
3. Enter or select parameters and confirm with ENTER.

4. To program another bend: press Yes (S4) and repeat step 3.
5. Repeat step 4 until all the desired bends are programmed.
6. Press No (S5).
7. To close the program: press End.
8. Enter the "Product number PN" and "Drawing number DN" and
confirm with ENTER.
The program is created and loaded (AUTOMATIC MODE).
B561EN04.DOC 8BCreating a program 4-21

8.2 Interlinking two programs
Two existing programs can be interlinked. They are consecutively

processed in automatic mode.

2. Load a program that is to be linked with another program
(see section 7, p. 4-20).
3. Select "4. Program editing".
Note
4. Under "CN linking", enter the product number of the program

with which this one is to be linked and confirm with ENTER.
5. Press End.
The programs are interlinked.
4-22 8BCreating a program B561EN04.DOC

(drawing profile)
Simple profiles can be graphically drawn and programmed at the

machine. The bending sequence can be calculated and adapted.
Creating program 1. Select PROGRAMMING MODE.

2. Select the 1. Product input.
3. Enter the parameter and confirm with ENTER.
– "Product number".
– "Drawing number" (drawing number can also comprise
letters (see section 5, p. 4-15)).
4. Enter the parameter and confirm with ENTER.
Parameter Description
"Thickness" ¾ Enter the sheet thickness.
"Material" ¾ Enter the material number or select a material from

the list.
"Length" ¾ Enter the bend length.
"Dimensions" ¾ Select the inner and outer dimensions.
Tab. 4-10
The first segment of the profile is displayed.

The value to be entered is displayed in the information cell
below.
Drawing the profile Note

The currently active segment of the profile is marked with a
circle.
Segments can be marked using cursor keys.
5. Enter the length of the segment and confirm with ENTER.

6. Enter the angle and confirm with ENTER.
7. Repeat steps 5 to 6 until all the segments of the profile have
been drawn.
Deleting segments 8. To delete a marked segment: press Delete (S1).
Drawing round bending 9. To draw a round bending: press Round bending (S2).
– Enter the angle and confirm with ENTER.
– Enter the radius and confirm with ENTER.
– Enter the number of segment and confirm with ENTER.

Modifying data subsequently 10. TO modify the program data subsequently: press Modify data
(S3).
– Modify data.
– Confirm with ENTER.
– Press End.
Calculate bending sequence Note

Machine parts and tools must be programmed (graphical).
11. Select Bending sequences (S5).

– Enter or select "Lower tool" and confirm with ENTER.
– Enter the number of the "Beam" and confirm with ENTER.
– Enter or select "Upper tool" and confirm with ENTER.
The profile with tool is displayed.
The last possible bending is displayed. Other options are
marked with a circle.
12. Adjust the bending sequence.
SOFTKEY Description
Select other bend as the Select the bend with the cursor keys and confirm
last bend: with ENTER.
Unbending (S1) Display the previous bend.
All bending lines are marked with a circle.
Bending (S2) Display the next bend.
All bending lines are marked with a circle.
Finger displacement Displace the gauge finger.
(S3)
Rotation (S4) Rotate bending part.
Lock on/off (S5) Switch the collision check on or off.
Rake (S6) Calculate the bending sequence automatically.
Saving (S7) Save the bending sequence.
The effective length of the profile is displayed.
Tab. 4-11
13. Press Next>> (S8).
4-24 8BCreating a program B561EN04.DOC

14. To display a graphical overview of the bending sequence:
press Bending sequence (S1).
SOFTKEY Description
Lock on/off (S4) Switch the collision check on or off.
The information cell on the screen displays
whether the collision check is switched on or off.
Jumping bend (S5) Replacing the bending sequence.
1. Press Jumping bend. (S5).
2. Mark the bend using the cursor keys.
3. Select the marked bend using ENTER.
4. Mark the second bend using the cursor keys.
5. Confirm with ENTER.
Moving bend (S6) Moving bends.

6. Press Move bend (S6).
7. Mark the bend using the cursor keys.
8. Select the marked bend using ENTER.
9. Move the marked bend to the right using the
cursor keys.
10. Confirm with ENTER.
Tab. 4-12
15. Press End.

16. Press End.
17. Press End.
The program is created.

9. Modifying the program
Existing programs that were created at the machine can be

modified.

2. Select "5. Product overview".
3. Load the desired program (see section 7, p. 4-20).
4. To modify a graphically created program: select "2. Product
editing".
5. To modify a manually created program: select "4. Product
editing".
6. Modify parameters.
7. Press End.
10. Programming individual bends
Reduction values are not calculated or used from the table in the
manual mode. All dimensions are used as inner dimensions.
Note
With ? open the control system help. A help text is displayed for
the selected field (see section 4, p. 4-15).
1. Press MANUAL MODE.

2. Enter or select the desired parameters and confirm with
ENTER.
3. To carry out the bending: press START.
4-26 9BModifying the program B561EN04.DOC

11. Creating a tool
Up to 99 tools can be stored at the control system, including

30 upper tools and 30 lower tools each.
Tip
To create a new tool: copy an existing tool (from the USB data
carrier, see section 13, p. 4-31) to an empty entry and modify it.

2. Select "7. Upper tools" or "8. Lower tools".
3. Mark the empty list entry.
4. Press Modify tool (S8).
Drawing lower tool 5. Enter the dimensions of the tool and confirm with ENTER.
1 Tool height 3 V-opening

2 V angle 4 Radius
Fig. 52850
B561EN04.DOC 11BCreating a tool 4-27

Drawing upper tool 6. Enter the dimensions of the tool and confirm with ENTER.
1 Tool height 2 Tool angle

Fig. 52849
7. Enter the length and angle of the individual segments of the

tool drawing.
The currently active segment of the tool drawing is marked with
a circle.
Deleting a segment 8. To delete a marked segment: press Delete line (S3).
Drawing a tool completely 9. To draw the tool completely automatically: press auto com-
pletion (S1).
The left side of the tool is completely drawn automatically.
10. Press auto completion (S1).
The right side of the tool is completely drawn automatically.
Modifying data 11. To modify the tool data: press Modify data (S3), modify the
data and confirm with ENTER.
Deleting tools 12. To delete the tool drawing completely: press Delete drawing
(S4).
13. Press End.
14. Press End.
15. Press End.
The tool is created.
4-28 11BCreating a tool B561EN04.DOC

12. Program Management
The following program management options are available:

• Save the programs from the machine directory on to a USB
data carrier.
• Save the programs from the USB data carrier in the machine
directory.
1. Connect the USB data carrier to the control panel.

3. Select "6. Save product".
Saving data on a USB data 4. To save data from the machine directory on to a USB data
carrier carrier: mark the desired function using the cursor keys.
Fig. 52847
Saving data in the directory 5. To save data from the USB data carrier in the machine
directory: mark the desired function using the cursor keys.
Fig. 52848
6. Select Save products (S1).

7. Select the directory in which data is to be loaded or whose
data is to be saved.
B561EN04.DOC 12BProgram Management 4-29

8. Select the program.
Softkey Description
all (S3) Mark all programs from this directory.
Backup directory (S4) Create, change, and delete a directory.
Drawing no (S5) Changeover between the following program
selection options:
• Product number.
• Drawing numbers.
local directory (S7) Display the overview of the folders created in the
machine directory.
View (S8) normal Display bending programs in a
directory (S4) list.
Dir expand Display bending programs in a list
(S5) with details.
graph dir (S6) Display a graphical preview of the
bending programs.
Tab. 4-13
9. Press ENTER.
The data is saved either on the USB data carrier or in the
machine directory.
Reloading saved data 10. To run a backup of the already saved data: press Read
products (S2).
11. Press End.
4-30 12BProgram Management B561EN04.DOC

13. Tool data management
The following tool data management options are available:

• Save the tool data from the machine directory on to a USB
data carrier.
• Save the tool data from the USB data carrier in the machine
directory.
1. Connect the USB data carrier to the control panel.

3. Select "12. Save tools".
Saving data on a USB data 4. To save data from the machine directory on to a USB data
carrier carrier: mark the desired function using the cursor keys.
Fig. 52845
Saving data in the directory 5. To save data from the USB data carrier in the machine
directory: mark the desired function using the cursor keys.
Fig. 52846
6. Press Backup directory (S4) and select the directory in which

data is to be loaded or whose data is to be saved.
7. Select data.
Softkey Description
all (S3) Mark all the data from this directory.
Backup directory (S4) Create, change, and delete a directory.
local directory (S7) Display the overview of the folders created in the
machine directory.
Tab. 4-14
B561EN04.DOC 13BTool data management 4-31

8. Select Save tools (S1).
The data is saved either on the USB data carrier or in the
machine directory.
Reloading saved data 9. To run a backup of the already saved data: press Read tools
(S2).
10. Press End.
4-32 13BTool data management B561EN04.DOC

14. Changing the language

2. Select "11. Program data".
Changing the language of the 3. Select "Language (LA)" or the enter the number of the desired
control system language.
Modifying the language of the 4. Select "Language help (HL)" or enter the number of the
Online help desired language.
5. Press End.
6. Press End.
15. Setting the program data

Note
Observe the Online help at the control system.
3. Set the program data.
4. Press End.
5. Press End.
B561EN04.DOC 14BChanging the language 4-33

16. Switching between MSC and ASV
Bending programs are processed in automatic mode. The rear stop

can be traversed with two methods:
• Manual increment switching (MSC):
– To move the backgauge to the next stop position after the
bending, press the BEAM DOWN foot switch. Then trigger
the next stroke.
• Automatic Safety Path System (ASV): the backgauge travels
automatically to the next stop position at the end of the
bending operation.
– If the target point is located within a defined safety range,
then the backgauge will travel to the stop position from
above with maximum speed. The danger of squeezing and
crushing is avoided by a hinged rear stop finger.
– If the start and target points are located outside the defined
safety range, then the backgauge will travel with maximum
speed directly to the stop position.
50
Vmax
Vmax
B
B
Vmax Vmax
B
A B
A
A A
50
A Start position B End position Vmax Maximum speed

Traversing examples Fig. 39381
Note
4-34 16BSwitching between MSC and ASV B561EN04.DOC

If it is not possible to work with the "Automatic Safety Path System"
(ASV), then a corresponding message is displayed on the user
interface. The "Manual increment switching" (MSC) method must
be traversed in such cases.
16.1 Switching from ASV to MSC

2. Enter 19 and press ENTER.
3. Enter the "access code" 14753 and press ENTER.
"Machine parameter" is opened.
5. Select "1. General parameters".
6. Use Next page (S2) to select "Sequencer options".
7. Select the parameter "M_OPTION17".
9. Press End.
9. Press End.
9. Press Next (S5).
The control system reboots.
"Program data" will open.
11. Use Next page (S2) to select the "Production settings".
12. Select the parameter "Between X for Z movement... XS".
14. Select parameter "Between R for X movement... RS".
16. Press End.
16.2 Switching from MSC to ASV

3. Enter the "access code" 14753 and press ENTER.
"Machine parameter" is opened.
5. Select "1. General parameters".
6. Use Next page (S2) to select "Sequencer options".
B561EN04.DOC 16BSwitching between MSC and ASV 4-35

7. Select the parameter "M_OPTION17".
9. Press End.
9. Press End.
9. Press Next (S5).
The control system reboots.
"Program data" will open.
11. Use Next page (S2) to select the "Production settings".
12. Select the parameter "Between X for Z movement... XS".
14. Select parameter "Between R for X movement... RS".
16. Press End.
16.3 Programming step change
If ASV is active, various step change options can be differentiated

(step change = moving the backgauge to the next position).
1. Select MANUAL MODE or PROGRAMMING MODE.

Note
3. Enter or select the desired step change method under "Code
CX".
4. Press ENTER.
4-36 16BSwitching between MSC and ASV B561EN04.DOC

17. Bending workpieces
Information
• The backgauge traverses automatically at the end of the
bending operation when working with ASV (Automatic Safety
Travel Speed System).
– If ASV is not possible, a corresponding message is
displayed on the user interface. Traversing must be done
with "Manual increment switching" in such cases (see
section 16.1, p. 4-35).
• When working with MSC (manual increment switching), the
BEAM DOWN foot switch must be pressed after each bend to
move the backgauge.
Prerequisite
• The desired bending part has been loaded (see section 7,
p. 4-20).
1. Press AUTOMATIC MODE.

2. Select the desired operation mode at the operation mode
selection key switch.
3. Press START.
4. Place workpiece between upper and lower tool and bring it
against the backgauge.
5. To move the beam downwards: press the BEAM DOWN foot
switch.
B561EN04.DOC 17BBending workpieces 4-37

18. Bending workpieces step by step
Every bend is individually executed in the step-by-step operation.

Every bend must be actively started using the BEAM DOWN foot
switch
Prerequisite
• The desired bending part has been loaded (see section 7, p. 4-
20).
1. Press STEP-BY-STEP OPERATION.

2. Select the desired operation mode at the operation mode
selection key switch.
3. To select a bend: select the desired bend using Previous bend
(S1) or Next bend (S2).
4. Press START.
5. Place workpiece between upper and lower tool and bring it
against the backgauge.
6. To move the beam downwards: press the BEAM DOWN foot
switch.
A program bending is carried out. The beam stops.
The control system switches to STOPP.
Depending on the program data setting, either the current bend
is retained or the next bend is displayed (Programming
mode>7. Program data> Production settings> Auto Bending
change (step) CS).
7. To carry out more bendings: repeat steps 3 to 6.
4-38 18BBending workpieces step by step B561EN04.DOC

19. Moving axes manually
The machine axes can be shifted manually with the JOG buttons.
1. Set the key switch for operation mode selection to "Setup

mode" (see section 1.3, p. 4-5).
2. Press MANUAL MODE, AUTOMATIC MODE or STEP-BY-
STEP OPERATION.
3. Press Manual Pos (S7).
4. Select the desired axis.
5. Move the axis with the JOG buttons.
Tip
To move the selected axis faster, press the JOG button -+.
6. Press End.
B561EN04.DOC 19BMoving axes manually 4-39

4-40 19BMoving axes manually B561EN04.DOC
Chapter 5
Setting work
1. Adjusting gauge finger.................................................. 5-3
1.1 Adjusting gauge finger for manual Z axis ........................ 5-3
2. Setting up tools.............................................................. 5-4

2.1 Loading upper tools ......................................................... 5-4
Loading upper tools with manual tool clamping ......... 5-5
Loading upper tools with TRUMPF Quick Clamp
(optional)..................................................................... 5-6
Loading upper tools in case of pneumatic tool
clamping (optional) ..................................................... 5-8
2.2 Loading lower tools.......................................................... 5-9
Loading lower tools with manual tool clamping .......... 5-9
Loading lower tools in case of pneumatic tool
clamping (optional) ................................................... 5-10
3. Segments of the upper tool holder ............................ 5-11

3.1 Dismantling segment ..................................................... 5-11
3.2 Installing segment.......................................................... 5-12
B561EN05.DOC 0BSetting work 5-1

Dismantling BendGuard ........................................... 5-13
Installing BendGuard ................................................ 5-14
Setting the height of BendGuard .............................. 5-16
Checking the laser beam.......................................... 5-17
4.2 Light curtain ................................................................... 5-18
Aligning transmitter and receiver .............................. 5-18
Checking the function of the light curtain ................. 5-19
5-2 0BSetting work B561EN05.DOC

1. Adjusting gauge finger
All CNC-controlled axes can be programmed freely using the

control system (see Chapter: Control system instruction manual").
With the optional CNC-controlled Z1-/Z2 axis, adjustment of the

gauge fingers is carried out automatically.
1.1 Adjusting gauge finger for manual

Z axis
Prerequisite
• The machine is ready for operation.
Press MANUAL OPERATION or PROGRAMMING OPERATION.

Press Machine function (S8).
1. Press Finger adjustment ON (S7).
The beam moves upward.
"Backgauge finger adjustment active" appears on the screen.
2. Press START.
The backgauge moves towards the front to a safe position in
front of the tool level.
3. Position gauge fingers.
4. Press Finger adjustment OFF (S7).
The backgauge travels back to its programmed position.
B561EN05.DOC 1BAdjusting gauge finger 5-3

2. Setting up tools
The TruBend Series 3000 press brakes are equipped with manual,
pneumatic or quick clamping.
2.1 Loading upper tools
Inadequately fixed upper tools can fall out of the clamps!

Risk of injury.
¾ Check the fastening of the upper tools after tool
Warning replacements.
There is a risk of objects or body parts being caught

between the upper tool and the machine frame.
¾ Do not load upper tools laterally over the upper tool holder.
Warning
5-4 2BSetting up tools B561EN05.DOC

Loading upper tools with manual tool
clamping
Prerequisite
• The back stops and clamping surfaces of the tools are clean.

• Size 8 Allen key.
Clamping upper tools

1 1
1 Socket head screws

Fig. 52973
1. Open the beam with the EMERGENCY-UP foot switch so that

tools can be easily positioned.
2. Loosen the hexagonal socket screws on the tool clamping.
3. To load upper tools:
¾ Insert the upper tool vertically with Safety-Click and
position it.
or
¾ If BendGuard is loaded: raise BendGuard until it stops and
locks into place.
¾ Push in the upper tool from the side without Safety-Click
and position it.
¾ Raise BendGuard once again and then lower it manually.
4. Tighten the hexagonal socket screws and fix the upper tool.
B561EN05.DOC 2BSetting up tools 5-5

Centering upper tools Note
The upper tool holder for TRUMPF tools is self-centering.
5. Upper tools that are not self-centering must be aligned by

means of an idle stroke before the first bending operation.
Loading upper tools with TRUMPF

Quick Clamp (optional)
Prerequisite
TRUMPF Quick Clamp Fig. 52439

2. Open the tool clamping using the quick clamping lever.

position it.
or
locks into place.
and position it.
4. Close the tool clamping using the quick clamping lever.



Loading upper tools in case of pneumatic
tool clamping (optional)
Pneumatic upper tool clamping, uniform Fig. 50411

2. To open the tool clamping: press Loosen OW (S5).
position it.
or
locks into place.
and position it.
4. To close the tool clamping: press Clamp OW (S5).



2.2 Loading lower tools
Lower tools are heavy and can slip out of your hands.
Danger of crushing.
¾ Wear safety shoes.
Warning
Note
There is a notch on one side of symmetrical TRUMPF lower tools.
This notch must be visible on the front side after loading the tools.
Loading lower tools with manual tool

clamping
Prerequisite

1 1 1
1 Socket head screws

Fig. 52974

2. Loosen the hexagonal socket screws at the terminal strip.
3 Insert and position lower tools vertically.
4. Re-tighten the hexagonal socket screws and fix the lower tools.
Loading lower tools in case of pneumatic

tool clamping (optional)

2. To open the tool clamping: press Loosen UW (S6).
3 Insert and position lower tools vertically.
4. To close the tool clamping: press Clamp UW (S6).

3. Segments of the upper tool holder
Note
The segments of the upper tool holder are aligned to each other. If
the tools are not always installed in the same sequence, it can lead
to inaccuracies when bending.
Segments of clamping are heavy and can slip out of your

hands.
Danger of crushing.
Warning ¾ Wear safety shoes.
3.1 Dismantling segment

1 1
1 Socket head screws 2 Distance between the segments

Segments of pneumatic upper tool holder Fig. 52851
1. Loosen hexagonal socket screws (1) and when doing so, hold
the segment of the clamping.
2. Remove the segment in a downward direction.
3. Tighten the hexagonal socket screws.
Tip
Number the segments of the upper tool clamping on the rear side
and position of the segment on the beam.
B561EN05.DOC 3BSegments of the upper tool holder 5-11

3.2 Installing segment

1 1

1. Loosen the hexagonal socket screws.

2. Insert the segment from below and hold it.
3. Tighten the hexagonal socket screws.
Tip
Number the segments of the upper tool clamping on the rear side
and position of the segment on the beam.
5-12 3BSegments of the upper tool holder B561EN05.DOC

4. Optoelectronic safety devices
4.1 TRUMPF BendGuard
Dismantling BendGuard
Note
When the BendGuard is removed, the beam can only be moved at
working speed (max. 10 mm/s).

1 Plugs for BendGuard 3 Hexagonal socket screw (5) of

2 Hexagonal socket screw (6) the cover plate
Fig. 52853

1. Move beam to mute point.
2. Disconnect the plug (1).
3. Loosen the hexagonal socket screw (3).
4. Remove the cover plate.
5. Loosen the hexagonal socket screws (2).
6. Remove BendGuard.
Installing BendGuard

1 Plugs for BendGuard 3 Hexagonal socket screw (5) of

2 Hexagonal socket screw (6) the cover plate
Fig. 52853

Connecting BendGuard to 1. Switch off the machine in the correct manner and switch off the
the machine MAIN SWITCH.
2. Position BendGuard and align it vertically.
3. Tighten hexagonal socket screw (2).
4. Connect the plug (1).
Note
Ensure that the position of the BendGuard cable is correct.
5. Mount the cover plate and tighten the hexagonal socket screw
(3).

Setting the height of BendGuard
BendGuard magnetic bolts Fig. 43075
1. Read the workpiece height on the used upper tool:
1 Tool height
Upper tool Fig. 30199
2. Fix BendGuard using magnetic bolts.

Checking the laser beam
If the laser beam B is above 14 mm, the machine no longer

stops within the braking distance!
Amputation of body parts possible.
Warning ¾ Readjusting the laser beam.
A check must be made after each tool change and at regular

intervals to determine whether or not laser light B is positioned
14 mm below the upper tool tip:
Checking the laser beam Fig. 35726
Note
Laser light B must be positioned precisely 14 mm (±0.5 mm)
underneath the upper tool tip.
¾ Hold the platelet centered under the tool tip.

The red laser light B is positioned 14 mm under the upper tool tip.
This position test must be correct for the entire length of the
machine.

4.2 Light curtain
Aligning transmitter and receiver
The transmitter and receiver must be in exact alignment to one

another. If they are not in exact alignment, the machine stops. The
following problems can occur:
• It can cause an interruption if the light from the transmitter
does not completely hit the receiver (too little light).
• If barely sufficient light hits the receiver, minimal contamination
can lead to interruptions.
The problems mentioned above trigger a machine stop. To avoid

this, it is necessary to align the transmitter and receiver exactly.
The transmitter and receiver are fastened with fixed holding
brackets, which specify the alignment extensively.
Note
When the laser alignment aid AR 60 is used, proceed according to
the description included with the device.
Aligning the transmitter 1. Align transmitter and receiver to each other.

2. Switch on power supply.
3. Swivel transmitter forwards until the red LED on the receiver
lights up and the green LED goes out.
4. Note the position of the transmitter.
5. Swivel transmitter back until the red LED on the receiver lights
up and the green LED goes out.
6. Note the position of the transmitter.
7. Fix the transmitter in the center of the swiveling range
(positions from steps 4 and 6).
Aligning the receiver 8. Swivel the receiver forwards until the red LED lights up and the
green LED goes out.
9. Note the position of the receiver.
10. Swivel the receiver back until the red LED lights up and the
green LED goes out.
11. Note the position of the receiver.
12. Fix the receiver in the center of the swiveling range (positions
from steps 9 and 11).

Checking the function of the light curtain
Even if the red LED does not light up, the beam moves down
in rapid speed!
¾ If when checking function the green or yellow transmitter
Warning LEDs only at one point, work may not be continued with the
machine.
Note
The light curtain must be checked daily before starting the
production.
¾ Move the supplied test bar within the field of protection

markings in the middle between transmitter and receiver slowly
through the whole field of protection.
The red LED on the receiver lights up.

Chapter 6
Maintenance
1. General guidelines......................................................... 6-3
2. Maintenance overview................................................... 6-4
3. Lubrication ..................................................................... 6-5

3.1 Overview .......................................................................... 6-5
3.2 Maintenance instructions ................................................. 6-7
Hydraulic system ........................................................ 6-7
X axis guide rail ........................................................ 6-12
R axis guide rail ........................................................ 6-13
Ballscrew .................................................................. 6-14
Z axis guide rail......................................................... 6-15
4. Hydraulic components ................................................ 6-16

4.1 Overview ........................................................................ 6-16
Hydraulic hose lines ................................................. 6-17
B561EN06.DOC 0BMaintenance 6-1

5. Pneumatic components .............................................. 6-18
5.1 Overview ........................................................................ 6-18
Compressed air filter with water separator............... 6-19
6. Mechanical components ............................................. 6-21

6.1 Overview ........................................................................ 6-21
Upper and lower tool holders.................................... 6-22
Z axis guide rail......................................................... 6-24
Z axis toothed belt (with optional 4-axes
backgauge) ............................................................... 6-24
X axis fixed stop ....................................................... 6-25
7. Electrical components ................................................ 6-26

7.1 Overview ........................................................................ 6-26
Safety switch of the protective covers ...................... 6-28
Failsafe control system PCSS-F............................... 6-29
Electrical cables........................................................ 6-30
Switch cabinet........................................................... 6-31
Optoelectronic safety device .................................... 6-31
6-2 0BMaintenance B561EN06.DOC

1. General guidelines
Appropriate maintenance is a prerequisite for maintaining the

quality of the machine. It prevents operational malfunctions and
their consequences.
Risk of injury when carrying out maintenance work when the

machine is switched on.
¾ Unless expressly stated otherwise:
Danger – Switch off the MAIN SWITCH.
– Lock the MAIN SWITCH.
– Remove the key.
¾ Strictly observe the safety regulations.
Notes on cleaning • Clean the entire system at regular intervals.

• Brush off large particles of dirt or remove them with an
industrial vacuum cleaner.
• Lightly grease the cylinder pistons when cleaning the machine
and whenever whistling noises occur:
– Remove the cover of the cylinders.
– Move the beam to the lower stop position.
– Lightly grease the cylinder pistons. Suitable grease can be
obtained from TRUMPF.
Notes on lubrication Refer to the lubrication chart and maintenance instructions for the
lubrication of the machine. The following points should also be
observed:
• Do not leave filler and drainage caps open for longer than
necessary and keep them clean at all times.
• Drain waste oil only at operating temperature.
• Use only lint-free cleaning cloths and low-viscosity spindle oil
("scavenge oil") to clean oil chambers and lubricating points.
Do not use cleaning wool, kerosene or benzene.
• Do not mix synthetic lubricating oils with mineral oils or
synthetic oils from other manufacturers, even if the synthetic oil
in question has equivalent properties.
• Dispose of waste oil properly.
B561EN06.DOC 1BGeneral guidelines 6-3

2. Maintenance overview
Interval Maintenance point Maintenance work Page

(operating
hours)
8 Hydraulic oil level indicator Checking the oil level 6-7
8 Hydraulic oil filter Checking for text message on the control 6-7
system display
8 Safety switch on protective covers Checking functions 6-28
40 Upper and lower tool holders Cleaning 6-22
40 Guide rail for gauge finger displacement Cleaning 6-24
(Z axis)
40 Pneumatic maintenance unit Draining condensation water 6-19
500 Hydraulic oil filter Changing the oil filter 6-8
500 X axis guide rail Lubricating 6-12
500 R axis guide rail Lubricating 6-13
500 Z axis guide rail Lubricating 6-15
500 Ballscrew Lubricating 6-14
500 Toothed belt of Z axis Checking 6-24
(with optional 4-axis backgauge)
500 Fixed stop of X axis Checking 6-25
500 Upper and lower tool holders Check the distance between the segments of 6-23
the tool clamping and adjust it if required
1000 Electrical cables Checking 6-30
1000 Switch cabinet Cleaning, checking 6-31
2000 Hydraulic hoses Checking 6-17
5000 Hydraulic oil filter Changing oil filter, analyzing oil 6-8
20000 Hydraulic system Changing oil 6-10
Every three Failsafe control system Replacing battery 6-29
years
If required Optoelectronic safety device Cleaning the transmitter and receiver 6-31
If required Pneumatic maintenance unit Cleaning the compressed air filter 6-20
Tab. 6-1
For single-shift operation:
eight operating hours Daily
40 operating hours Weekly
500 operating hours Three months
1000 operating hours Six months
2000 operating hours Annually
5000 operating hours After 2.5 years
20000 operating hours After 10 years
Every three years After 3 years, regardless of the
number of operating hours
Tab. 6-2
6-4 2BMaintenance overview B561EN06.DOC

3. Lubrication
3.1 Overview
h
500
1 2 4 3
1 R axis recirculating ball unit 3 Z axis recirculating ball unit 4 X axis recirculating ball unit
2 Ballscrew
Lubrication chart for 2-, 4- and 5-axis backgauges Fig. 43043
Specification of the Monitor oil level and,

lubrication intervals in if necessary, top up to
h operating hours required level
Reading the Checking the oil level
maintenance
instructions
Lubrication with Emptying the container
a grease gun
Lubrication with oil can Replacing the contents

or spray can of the container
Tab. 6-3
B561EN06.DOC 3BLubrication 6-5

Note
Established equivalent lubricants from other manufacturers can
also be used. However, different types of oil may not be mixed.
Ladders leaning against the machine can easily fall over!

¾ For maintenance work that requires climbing equipment, use
a stepladder.
Caution
In case of oil replacement and other maintenance activities

that are carried out immediately after machine operation, the
temperature of the oil can be up to 80°C.
Warning Danger of burns
¾ Implement suitable safety measures.
Lubrication point Quantit Recommended lubricant Identification Viscosity,

y [l] consistency
Hydraulic system • Aral Vitam DE 46 CL, HL, HLP, ISO VG 46
• BP Energol HLP-D 46 HLPD
3066 100 • CASTROL Hyspin AWH-M 46
3120 200 (initial filling)
3180 250 • Elf Elfolna HMD 46
• ESSO HLPD oil 46
• Mobil hydraulic oil HLPD 46
• SHELL Tellus Oil 46
Ballscrew • SHELL Alvania EP2 KP2K-20 NLGI 2
• MOBIL Mobilux-EP2
X axis recirculating • SHELL Alvania EP2 KP2K-20 NLGI 2
ball unit • MOBIL Mobilux-EP2
R axis recirculating • SHELL Alvania EP2 KP2K-20 NLGI 2
Z axis recirculating • SHELL Alvania EP2 KP2K-20 NLGI 2
Tab. 6-4
6-6 3BLubrication B561EN06.DOC

3.2 Maintenance instructions
Hydraulic system
(see Overview, p. 6-5)
Checking the oil level Maintenance interval: 8 operating hours.
1 Marking min/max
Oil level indicator Fig. 52978
1. Press HYDRAULIC SYSTEM ON.

The hydraulic pump of the machine is switched on.
2. Check oil level.
The oil level must be between the upper and lower marks of the oil
level indicator.
Checking the contamination Maintenance interval: eight operating hours.

of the oil filter
¾ Check for text message on the control system display.
The oil filter must be replaced if a text message appears on the
control system display.

Changing the oil filter Maintenance interval: 5000 operating hours.
Information
• The oil filter needs to be changed more frequently with a new
machine.
– First oil filter replacement after 500 operating hours.
– Second oil filter replacement after a total of 2500 operating
hours.
– Third oil filter replacement after a total of 5000 operating
hours.
• The oil filter must be replaced before time if a message to that
effect is displayed at the control system.
1 Hydraulic oil filter

Hydraulic oil pump with a hydraulic filter (from below) Fig. 52855
1. Switch off the machine correctly, switch off the MAIN SWITCH,
lock it, and remove the key.
2. Change the filter element of the hydraulic oil filter.
3. Check the filter housing.
4. Check the bypass valve.

Analyzing the hydraulic oil Maintenance interval: 5000 operating hours.
1. Change oil filter (see above).

2. Have the hydraulic oil examined by a lubricating agent
laboratory. Depending on the results, an oil change might have
to be carried out. The following analysis values are required:
– TAN (Total Acid Number).
– Viscosity
– Water content.
If the water content is >1000 ppm, then damage to compo-

nents has probably already been caused!
Corrosion of the machine
Warning ¾ Contact TRUMPF technical customer service.
3. The hydraulic oil must be changed if the analysis indicates at

least one of the following values (see below):
– TAN (Total Acid Number) >2.5.
– Viscosity <41.4 mm2/s or >50.6 mm2/s for ISO VG 46.
– Water content > 500 ppm.
Value Explanation/effect
TAN Oil ages; surface corrosion and deposits possible.
(Total Acid Number)
Viscosity Significant deviations in viscosity are a sign of severe
contamination and foul oil.
Water content The vapor pressure of water is significantly higher than
that of oil.
It can cause cavitation (vapor bubbles are created at
low pressure before the water condenses suddenly
(when pressure is increased)).
Tab. 6-5

Changing the hydraulic oil Maintenance interval: 20000 operating hours.
If the analysis of the hydraulic oil shows non-permissible values,

then the hydraulic oil needs to be changed earlier.

• Oil pump with integrated filter (optional, available from
TRUMPF).
• Drilling machine.
• Filter with a pore size of 3 μm.
Information
• Observe the applicable national safety guidelines and accident
prevention regulations (see "Safety" chapter).
• Only use the same type of oil as before for topping up.
• Replace the oil filter every time the hydraulic oil is changed.
Unfiltered oil destroys the hydraulic system!

Warranty claims are rendered void.
¾ Use filters with 3 μm pores to prefilter new oil.
Caution
1 Drain cock
Drain cock at the oil tank (from below) Fig. 52854

2. Connect tube to drain cock.
3. Drain waste oil into a container.
4. Pump new hydraulic oil from the oil drum into the oil tank of the
machine. When pumping the oil, pre-filter it using a filter with a
pore size of 3 μm.
5. Change the oil filter (see page 6-5).
6. Switch on machine and the hydraulic system.
7. Program individual bends in the MANUAL MODE.
8. Press START.
9. Carry out a 30 min bending stroke and monitor the process.
10. Check the oil level and top up the oil if necessary.

X axis guide rail
Lubricate the grease nipple Maintenance interval: 500 operating hours.
1 Grease nipples
Fig. 43044
2. Lubricate the grease nipples (1) using a grease gun.
3. Switch on the machine.
4. Move the X axis by 30 mm.
6. Repeat steps 2 to 4 three times.
Grease nipple lubricated in 4 different axis positions.

R axis guide rail
1 1
1 Grease nipples
Fig. 52859
2. Remove the cover plate on the front side of the backgauge by
sliding it upwards.
3. Lubricate the grease nipple (1) using a grease gun.
5. Move the R axis by 30 mm.

Ballscrew
1 Grease nipples
Fig. 43045
2. Remove the cover plate on the front side of the backgauge by
sliding it upwards.
3. Lubricate the grease nipple (1) using a grease gun.
5. Move the R axis by 30 mm.

Z axis guide rail
1 Grease nipples
Fig. 52852
2. Lubricate the grease nipples (1) using a grease gun.
4. Move the Z axis by 30 mm.

4. Hydraulic components
4.1 Overview
1 Hydraulic system hoses

Fig. 52856
6-16 4BHydraulic components B561EN06.DOC

Hydraulic hose lines
(see Overview page 6-16)
Checking the hoses Maintenance interval: 2000 operating hours.
Information
• The hydraulic hose lines should be checked by an expert to
assure safe operating condition. They should also be checked
before the machine is put into service for the first time.
A specialist is someone who has completed an appropriate
training course (e.g. TRUMPF training course "Certificate of
qualification - Pressure vessel regulations").
• In addition to the above information, the relevant national
safety regulations and safety guidelines for hydraulic hoses
(order no. ZH 1/74) should be observed and maintained.
Publisher:
Commercial and industrial employer's liability insurance
association membership corporation P. O. box 20 52
53757 St. Augustin
Sales:
Carl Heymanns Verlag KG
Luxemburger Str. 449
50939 Köln
2. Check the hydraulic hoses for defects. Possible defects:
– Damage on the outer layer extending to the inner lining
(e.g. abrasions, cuts, or tears).
– Brittleness of the outer layer (crack formation of the hose
material).
– Deformations not corresponding to the natural form of the
hose in a depressurized or a pressurized state or when
bent (separation of layers, blistering, crushed or bent
areas).
– Leaks
– Installation requirements not observed.
– The hose dislodging itself from the fittings.
– Damage or distortion of the fittings which diminishes
function and stability of the fittings or impairs the
connection between hose and fittings.
– Corrosion of the fittings that impairs the functionality and
stability.
– Expired storage time or service life (according to ZH 1/74).
B561EN06.DOC 4BHydraulic components 6-17

5. Pneumatic components
5.1 Overview
1 Compressed air filter with water separator

Fig. 52975
Note
A pneumatic system is available only if the machine has a
pneumatic tool clamping.
6-18 5BPneumatic components B561EN06.DOC

Compressed air filter with water separator
(see Overview page 6-16)
Draining condensation water Maintenance interval: 40 operating hours.
The pressure filter with water separator removes moisture from the
air as well as hard particles such as dust, scale and rust.
1 Compressed air filter with water

separator
Fig. 52976
1 Filter cartridge 3 Drain

2 Sight glass
Fig. 2109
B561EN06.DOC 5BPneumatic components 6-19

2. Open the drain (3).
3. Position the tilted drain piece at the lower end of the sight glass
(2).
Condensation water drains off.
Cleaning the compressed Maintenance interval: as needed.

air filter
2. Close air supply.
3. Unscrew the sight glass (2).
4. Clean the sight glass (2) with water.
5. Dismantle filter cartridge (1).
6. Wash the filter cartridge (1) with kerosene or gasoline and blow
it dry from the inside to the outside with compressed air.
7. Install filter cartridge (1).
8. Install sight glass (2).
Note
If the filter cartridge is very contaminated, replace it (mat. no.
1279210).
6-20 5BPneumatic components B561EN06.DOC

6. Mechanical components
6.1 Overview
1 2 3 4 5
1 Tool holder for upper tool 3 Z axis toothed belt 5 Fixed stop of X axis
2 Tool holder for lower tool 4 Z axis guide rail
Fig. 52857
B561EN06.DOC 6BMechanical components 6-21

Upper and lower tool holders
(see "Overview", page 6-21)
Cleaning the tool holder Maintenance interval: 40 operating hours.
2. Clean the upper and lower tool holders with a lightly oiled cloth.
6-22 6BMechanical components B561EN06.DOC

Check the distance between Maintenance interval: 500 operating hours.
the segments of the tool
clamping and if required, Additional equipment, tools, material
adjust it
1 1

Note
The distance between the individual segments of the upper tool
holder should always be 2 mm.
2. Check the distance between the individual segments of the
upper tool holder (2).
Note
If the distance is more than or less than 2 mm, adjust it.
3. Unscrew the hexagonal socket screws (1x) of the segment.

4. Shift the segment.
5. Retighten the hexagonal socket screws (1).

Z axis guide rail
Cleaning guide rail Maintenance interval: 40 operating hours.
2. Clean the guide rail for the gauge finger adjustment using a
lightly oiled cloth.
Z axis toothed belt

(with optional 4-axes backgauge)
Checking the belt tension Maintenance interval: 500 operating hours.
2. Check the belt tension of the toothed belt of the R axis using a
traction and pressure scale.
In case of a 7 N load, the toothed belt may only yield:
– s = 20 mm (TruBend 3066/3180)
– s = 25 mm (TruBend 3120)
s
F
s value to the extent of which F Load on the toothed belt

the gear belt may yield
Z axis toothed belt Fig. 26490
6-24 6BMechanical components B561EN06.DOC

X axis fixed stop
Tightening screws Maintenance interval: 500 operating hours.
2. Tighten the fixing screws for the fixed stops using a torque
wrench set to 8 Nm.
Note
The fixed stops must be mounted in such a way that they can be
moved from the middle of path movement outwards. When moving
the X axis unit, it must be possible to move a fixed stop.

7. Electrical components
7.1 Overview
1 2, 3 4 5 4 5 4
1 DA control system 3 Switch cabinet with fail-safe control 5 Optoelectronic safety device
2 Electrical leads system
4 Safety switches of the protective
covers
Fig. 52858
6-26 7BElectrical components B561EN06.DOC

1
1 Control elements at the switch

cabinet
Fig. 52977
B561EN06.DOC 7BElectrical components 6-27

Safety switch of the protective covers
Checking the function Maintenance interval: 8 operating hours.
Be careful when switching on the machine again!

Risk of fatal injury.
¾ Before switching on the machine again, make sure that no
Danger one is within the danger zone of the machine.
1. Open the rear protective cover (roller gate) of the machine.

The hydraulic system of the machine shuts down
(EMERGENCY STOP function).
2. Open the side protective cover of the machine.
The hydraulic system of the machine does not shut down.
A closing movement of the beam is possible at a maximum of
10 mm/s.
If both protective covers at the side are opened, then the
hydraulic system of the machine shuts down (EMERGENCY
STOP function).

Failsafe control system PCSS-F
Replacing the battery Maintenance interval: Every 3 years, regardless of the number of
operating hours.
Risk of injury due to contact of the battery with eyes and

skin!
¾ Do not charge the battery.
Warning ¾ Do not use force to open battery.
¾ Do not throw batteries into fire.
¾ Dispose of the battery properly.

• Philips screwdriver
• Battery
CR 2430, Lithium 3V
TRUMPF mat. no.: 1365695
1
1
1
1
1 Screws
Fig. 52981

Note
If the battery is not replaced within 30 seconds, the data of the
control system software and that of the kernel is lost: contact
TRUMPF Service.
2. Remove all plugs at the PCSS.
3. Undo screws (1) on the cover of the PCSS.
4. Remove the battery and insert a new one within 30 s.
5. Install the cover and tighten the screws (1).
6. Re-install all the plugs.
Electrical cables
Checking lines Maintenance interval: 1000 operating hours.
2. Check the electrical cables for defects. Possible defects:
– Damage to or brittleness of the insulation.
– Deformations that do not correspond to the natural shape
of the cable (crushed sections, kinks,...).
– Incorrect installation of the cable.

Switch cabinet
Clean and check switch Maintenance interval: 1000 operating hours.

cabinet
2. Keep switch cabinet free of dust.
3. Check that all clamps are firmly in place.
4. Check protective contacts, replace any that are burnt out.
Optoelectronic safety device
Cleaning the transmitter and Maintenance interval: as needed.

the receiver
The front pieces of the transmitter and receiver must be cleaned
regularly depending on the surrounding conditions. If this is not
done the light that is sent and received can become so faint due to
contamination that it leads to the machine coming to a standstill
when this was not intended.

• Soft, clean cloth.
• Window-cleaning agent.
Note
For cleaning do not use any abrasive or aggressive agents.
2. Clean the disks of the transmitter and receiver with window
cleaning agent.
3. Do not polish the glass; just let it dry.

Chapter 7
Network card (optional)
B561EN07.DOC 0BNetwork card (optional) 7-1

7-2 0BNetwork card (optional) B561EN07.DOC
Delem
Networking
on the
DA-W control
-1-
Delem
Table of contents
1. Remote desktop between a pc and the DA-W control .................................................. 3

2. How to implement networking with the DA-W control................................................ 5
2.1. Network connection ................................................................................................... 5
2.2. Direct link between a control and a pc ....................................................................... 8
2.3. Modem connection between control and PC.............................................................. 9
2.4. How to arrange an incoming dial-up connection on Windows XP.......................... 10
3. Modem connection on DA-W control........................................................................... 14
4. Wireless networking on the control.............................................................................. 20
5. The Linksys Wireless Acces Point Router ................................................................... 21
6. The Linksys Wireless Ethernet Bridge......................................................................... 23
-2-
Delem
1. Remote desktop between a pc and the DA-W control

It is possible to establish a remote connection between the DA-W control and a remote pc,
meaning that the remote pc takes control of the DA-W control. In this situation the control
screen is visible on the remote pc. From the pc, the user can operate the Delem application or
switch to Windows and adjust settings there. If the Delem application is active, it is not
possible to switch between operation modes (manual mode, programing mode, etc.) and it is
also not possible to start or stop operation.
To enable remote operation, there must be valid TCP/IP connection between the control and
the remote pc. See the next section about the several ways to establish a valid connection.
The remote pc must be equipped with a software tool known as ‘Remote Display Control’.
This software can be obtained from the Website of Microsoft.
When the software is installed and a connection is active, proceed as follows:
• activate the application ‘Remote Display Control’ from theWindows Start menu. An
empty window will open, meaning that the software is waiting for a remote device to
report itself to the software;
• on the DA-W control, use the Windows Explorer to browse to the subdirectory
\Windows;
• in this directory, double-click the icon ‘CERdisp.exe’;
When activated, a message appears about the version of the software. Click ‘OK’ to continue.
the following window appears:
-3-
Delem
• In this Window, click on the button ‘Connect’. The following Window appears:
• In the field ‘hostname’ you should enter the name or the IP number of the remote pc to
which you wish to connect.
When this operation is succesfull, you will see the display of the control appear in a window
on the remote desktop pc. It is now possible to perform actions on the control from the remote
pc.
In case the connection between the pc and the control is done through a simple ‘crossed’ UTP
cable (Ultra Twisted Pair), you must enter the IP number of the remote pc. In other cases, it is
also possible to enter the name of the pc.
-4-
Delem
2. How to implement networking with the DA-W control

This section will describe different network possibilities for the DA-W control.
We will discuss three possible settings:
• Network connection
• direct link between a control and a PC through an ethernet cross-cable.
• modem connection between control and PC.
2.1. Network connection
In this case, the control is connected to a standard local network. From the user point of view,
this setting is the easiest alternative. When the control is started it will receive a network
addres (IP number) from the network server.
If the network is connected to the internet, internet browsing can be done through the network
connection. To obtain contact with other pc’s it is necessary to know which IP number they
got from the network server or which name they have.
Network
UTP UTP
PC
DA-W
control
In this situation, the network settings of the control must be as such, that the control will
obtain an IP number from the network server.
-5-
Delem
To check and adjust the network settings, open the Windows Control Panel. It should look as
follows:
In this screen, double-click the icon ‘Network and dial-up connections’. the following screen
appears:
-6-
Delem
This screen can also be entered directly from the start menu by scrolling to ‘settings’ and
choosing ‘Network and dial-up connections’.
The second icon, PCI-RTLxxxx, represents the built-in ethernet connector. To modify the
settings, select the icon, open the ‘file’ menu and select ‘properties’. A new window appears
in which the settings of the ethernet port can be edited.
Select the setting ‘obtain an IP address via DHCP’. This way, the control will receive an
address fom the server. Such a setting should be active on every pc, that is connected to the
same network.
If this setting is active and you wish to view your own network settings, double-click on the
network symbol in the Windows taskbar:
A window with network information will appear:
-7-
Delem
2.2. Direct link between a control and a pc
UTP (cross)
DA-W
PC control
In this situation, there is no network available. The pc and the control are connected directly
through a UTP cable. The cable should be a ‘crossed’ UTP cable.
As soon as the two machines are connected, click on the network symbol as shown before. In
the network information window, click on the button ‘Renew’. The IP number of the control
will change to 0.0.0.0. Now wait until the IP number changes again. It should change to a
number starting with 169.254.... Check the same on the pc. The control and the pc can still be
used for remote display operation. In this situation, however, you must enter the IP number of
the pc in the ‘connect’ dialog to get a connection.
-8-
Delem
2.3. Modem connection between control and PC
In this situation, the control uses a modem to make a dial-up connection to the remote pc.
Both systems are equipped with a modem.
Telephone network
Modem Modem
DA-W
PC control
The pc must be equipped with dial-up server software to accept incoming calls from the
control. From the control, a dial-up connection is initiated.
The procedure to initiate a dial-up connection on the control is explained in detail in chapter
3.
-9-
Delem
2.4. How to arrange an incoming dial-up connection on Windows

XP
- 10 -
Delem
- 11 -
Delem
Important:
Check these user accounts. When making the dial-up connection from the control, you must
have a valid username and password from one of these accounts to be able to make a
connection.
- 12 -
Delem
- 13 -
Delem
3. Modem connection on DA-W control

This chapter serves to describe how a modem connection is established on a Delem DA-60W
control. A DA-60W control is equipped with a Windows operating system which gives the
user the possibility to act as an internet client. In this description the assumption is made that
the control is not connected to an ethernet LAN but is equipped with a modem that is
connected to the serial port of he control. Through this modem, it is possible to make a dial-up
connection to an Internet Service Provider (ISP) and thus obtain access to the internet.
Of course, the control must also be equipped with an internet browser (i.e. Internet Explorer).
After making a valid internet connection, the browser should have no trouble browsing the
internet.
The settings for a dial-up connection are initiated from the appropriate control panel, which is
directly accessible from the Windows Start menu:
- 14 -
Delem
In the control panel, click 'make new connection'.
In the window that appears, select 'dial-up connection'. In the top of the window, type the
name you wish to give your connection.
Click 'next' to proceed.
- 15 -
Delem
In this window, select the correct modem from the pop-down list. For a standard modem, you
should select 'Hayes compatible on COM1:'. The name COM1: refers to the serial interface at
the side of the main board, with the standard 9-pole sub-D connector.
The button 'TCP/IP Settings' and the button 'Security settings' give access to more advanced
settings. If you are an experienced internet user, you could select these functions and enter
more specialised settings. If not, it is best to leave these functions alone at his time.
The button 'Configure' is used to adjust the modem settings.
Normally, most of these settings are correct, but you should check whether the baud rate is set
to the correct speed. Check your modem specifications for the correct settings. If correct, click
'OK' to return to the modem connection dialog. Click 'next' to continue.
The next window shows the phone number codes of your ISP: country code, area code and
phone number.
- 16 -
Delem
Make sure to enter these fields correct, so that the control will dial the correct number. When
the numbers are entered, click 'Finish'. The connection is created. When you look at the
screen, you will see an extra icon has been added with your connection name below it.
Your connection is not complete yet. Double-click the connection icon to open your
connection. In the dialog that appears, enter your user name and password with which you can
identify yourself to the ISP.
If you must use this connection often, it can be useful to select 'save password'. This way, the
connection is opened quickly when it is called for.
Click the button 'dial properties'.
- 17 -
Delem
A new window opens, in which area codes for several locations can be set. Enter the codes for
the appropriate area and country. When the control will start to dial the ISP, it will compare
the country and area code of the ISP with the codes that you have programmed here. When
those codes are the same (meaning the control is in the same area as the ISP), the control will
omit those codes from the dial string and dial the ISP directly. Click the button 'New' to
program a new location from where you will call.
Click the button 'Dialling patterns' to program the manner in which the control will dial the
ISP.
In this window, three methods are shown how to call the ISP:
• make a local call (the ISP is in the same area as the control)
• make a long distance call (the ISP is in a different area as the control, but still in the
same country)
• make an international call (the ISP is in another country)
When the call is made, the control will compare the dial codes of the ISP with the codes of the
control. Based on this comparison, the control will choose one of the dial methods: local, long
distance or international.
The characters E, F and G are used to represent the numbers for country, area and phone
number. A comma stands for a short pause before dialling. Any other character that is entered,
will be interpreted literally.
When a local call is made, the control will dial the number as is indicated in the first field. For
a long distance call, the directions in the second field are followed and for an international call
the directions in the third field are followed.
For example, the direction for a local call could be:
,G
- 18 -
Delem
As is indicated at the bottom of the screen, G represents the telephone number of the ISP. So
when the control has determined the ISP and the control are in the same area, the control will
simply dial the telephone number.
The directions for a long distance call could be:
,0FG
The string begins with a zero, because in the case of a long distance call the number must start
with a zero. The F stands for the area code and the G stands for the ISP number.
Example:
A Delem control has been installed in Eindhoven, the user wishes to contact its ISP in
Amsterdam. The local area code of Eindhoven (where the control is located) is 40, the country
code of the control 31 (the Netherlands).
The area code of the ISP is 20 (Amsterdam), the country code of the ISP is 31 (the
Netherlands), the number of the provider is 1234567.
When the connection icon is opened, the control will check the data of the ISP. He will
determine that the control and the ISP are in the same country but not in the same area, so the
directions for a long distance call must be followed:
,0FG
This string is interpreted as follows:
, = (short pause)
0=0
F = 20
G = 1234567
So upon 'connect', the modem will dial: 0 20 1234567.
When the settings have been entered correctly, click on 'OK' in the upper right corner of the
screen to return to the initial dial-up window. In this window, the resulting phone number is
displayed that will actually be called by the modem. Click 'connect' to start the call and open a
connection to your ISP.
- 19 -
Delem
4. Wireless networking on the control

It is possible to connect the control to a wireles network. For instance, through a wireless
ethernet bridge that translates network data between wired and wireless networks. The device
has a standard ethernet port to which a computer or a DA-W control can be connected.
Network Router
Wireless UTP Wireless
Wireless
ethernet
bridge
UTP
DA-W
control
This is another example of networking possibilities. Also in this case, the network protocol is
TCP/IP. Although the connection is made through a wirelesse device, the network
organisation is the same as described in section 2.1 concerning a normal network.
- 20 -
Delem
5. The Linksys Wireless Acces Point Router

This device is both a network hub and a small network server. It can supply network adresses
(IP-numbers) to all connected clients.
Network Router
Wireless UTP UTP
DA-W
control
A client (a pc or a DA-W control) can be connected through a UTP cable or through a

wireless connection. In both cases, a client receives an IP-number from the Router.
- 21 -
Delem
The settings of the Router can be adjusted, it necessary. For this purpose, the Router has a
small integrated webserver. This webserver can be from any of the connected clients through
their webbrowser. When a user attempts to connect, he will have to enter a username and
password. If these are entered correctly, a web page opens in which several router settings can
be adjusted.
Default, both the username and password of the Router are set to ‘admin’. For safety reaons,
you may wish to change this.
For wireless networking, the field ‘SSID’ may have to be edited. A network between wireless
devices will only function if these devices have the same SSID.
- 22 -
Delem
6. The Linksys Wireless Ethernet Bridge

This device translates network signals between a wired and a wireless network. As already
shown in the previous section, it enables a computer to connect to a wireless network.
Network Router
Wireless
X II
o WLAN
Wireless
ethernet
o LAN bridge
LAN
UTP
Points of interest when connecting:

• Make sure the bridge device has power
• Make sure the client (a pc or a DA-W control) is connected to the LAN port of the
bridge. If the LED with the indication ‘LAN’ is lit, the client is connected correctly. If
the LED is not lit, check your cabling. If the cabling is sound, change the setting of the
switch with the cross and the stripes.
• Make sure the device reognises the wireless network. If the LED with the indication
‘WLAN’ is lit, the wireless network is sound. If no wireless network is recognised, it is
possible that the several devices do not have the same SSID.
- 23 -
Index
2 D
2D.. ............................................................ 4-23 Danger ....................................................... 1-25
Danger zone ................................................ 1-6
Dies .....................................................3-18, 5-9
• Loading.................................................. 5-9
A
Ambient conditions ...................................... 2-6
Ambient temperature ................................... 2-6 E
ASV................................................... 1-21, 4-34
• Switching between MSC and ASV...... 4-34 EC Machinery Directive ......................1-4, 1-25
Axis EMERGENCY STOP ................................. 4-12
• Moving manually ................................. 4-39 Entering alphanumeric characters ............. 4-15
Entering letters........................................... 4-15
B
Backgauge.......................................... 3-6, 3-16
F
• 2-axis................................................... 3-17 Floor ......................................................2-4, 2-5
• 4-axis................................................... 3-17 • Base plate.............................................. 2-5
• 5-axis................................................... 3-17 • Floor requirements ................................ 2-4
Beam ........................................................... 3-9 Foot operation.............................................. 4-7
Bend, individual Foot switch..........................................3-15, 4-3
• Programming....................................... 4-26 • Activating ............................................. 4-11
BendGuard ....................................... 3-26, 4-16 • Additional lights ................................... 3-24
• Checking the laser beam .................... 5-17 Four-hand operation ...........................4-7, 4-10
• Installing .............................................. 5-14 Frequency .................................................... 2-8
• Magnetic plate..................................... 3-29 Fuse protection ............................................ 2-8
• Removal .............................................. 5-13
• Setting the height ................................ 5-16
BendGuard mode ...................................... 4-16
Bending...................................................... 4-37
• Step by step ........................................ 4-38
G
Gauge finger .......................................3-16, 5-3
• Adjusting gauge finger........................... 5-3
Grease nipple................. 6-12, 6-13, 6-14, 6-15
C
CE marking .................................................. 1-4
Connected loads.......................................... 2-8
Control panel ............................................. 3-12
Control system...........................3-13, 3-14, 4-8
Crowning.................................................... 3-10
• Hydraulic ............................................. 3-11
• Mechanical .......................................... 3-11
B561EN08.DOC Index 1
Maintenance ................................................ 6-4
• Ballscrew ............................................. 6-14
• Changing the oil filter............................. 6-8
• Check oil level ....................................... 6-7
• Failsafe control system........................ 6-29
H • Gauge finger displacement ................. 6-24
Humidity....................................................... 2-6 • Hydraulic hose lines ............................ 6-17
Hydraulic oil ............................................... 2-12 • Hydraulic system ................................... 6-7
Hydraulic system ......................................... 3-9 • Protective cover................................... 6-28
• Switch off............................................... 4-7 • R axis................................................... 6-13
• Switching on.......................................... 4-7 • Switch cabinet ..................................... 6-31
• Tool holder........................................... 6-22
• X axis................................................... 6-12
• X axis, fixed step ................................. 6-25
• Z axis ................................................... 6-15
• Z axis, toothed belt .............................. 6-24
I Manual operator console ....................3-25, 4-4
Inclined position of the beam....................... 3-9 • Activating ............................................. 4-11
Installation site............................................. 2-4 Modifying language.................................... 4-33
MSC ..................................................1-21, 4-34
• Switching between MSC and ASV ...... 4-34
K
Key switch O
• Description ............................................ 4-7
Occupational safety ................................... 1-29
Oil 2-12, 6-7
• Changing the oil .................................. 6-10
Oil quantity ................................................. 2-12
Oil temperature ............................................ 2-6
L Operating elements........................4-3, 4-5, 4-8
Operating mode keys................................... 4-9
Light curtain ...................................... 3-31, 4-16
Operating modes ....................................... 4-10
• Aligning transmitter and receiver ........ 5-18
Operator....................................................... 1-6
• Checking the function ......................... 5-19
Options....................................................... 3-24
Light curtain mode ..................................... 4-18
• 4-axes backgauge ............................... 3-17
Lower tool
• 5-axes backgauge ............................... 3-17
• Drawing ............................................... 4-27
• Additional foot switch........................... 3-24
Lubrication ................................................... 6-5
• BendGuard .......................................... 3-26
• Foot switch ............................................ 4-3
• Four-hand operation.....................4-7, 4-10
• Light curtain ......................................... 3-31
• Manual operator console..............3-25, 4-4
M • Manual tool clamping .......................... 3-20
• Network connection............................. 3-26
Machine ....................................................... 3-3 • Pneumatic tool clamping .....3-21, 5-8, 5-10
• Axes ...................................................... 3-7 • Quick Clamp .......................................... 5-6
• Operating without BendGuard ............ 4-19 • Robot operation..................................... 4-7
• Operating without light curtain ............ 4-19 • Support bracket ................................... 3-21
• Switching off........................................ 4-14 • Two-foot mode .................................... 4-10
• Switching on........................................ 4-12 • Two-foot operation ................................ 4-7
• Total weight........................................... 2-5 • Two-hand operation .....................4-7, 4-10
Machine axes .............................................. 3-7
Machine dimensions.................................... 3-4
Machine frame ............................................. 3-9
Magnetic plate ........................................... 3-29
2 Index B561EN08.DOC
Optoelectronic safety device ...3-26, 3-31, 5-13 T
• BendGuard................................. 4-16, 5-13
• Light curtain................................ 4-18, 5-18 Technical specifications ............................... 3-4
Optoelectronic safety devices.................... 4-16 Temperature range ...................................... 2-6
Tool
• Creating ............................................... 4-27
• Management ....................................... 4-31
• Saving.................................................. 4-31
Tool clamping............................................. 3-18
P • Manual......................... 3-19, 3-20, 5-5, 5-9
Personnel...................................1-6, 1-14, 1-28 • Pneumatic............................3-21, 5-8, 5-10
Pneumatic tool clamping ........................... 3-21 • Quick Clamp .......................................... 5-6
Power supply ............................................... 2-7 Tools .......................................................... 3-22
Program • Back up................................................ 4-31
• Back up ............................................... 4-29 • Setting up .............................................. 5-4
• Creating............................................... 4-21 • Special tools ........................................ 3-23
• Creating graphically ............................ 4-23 Total weight of the machine......................... 2-5
• Creating manually ............................... 4-21 Transport.................................................... 2-13
• Interlinking........................................... 4-22 Two-foot mode ........................................... 4-10
• Loading ............................................... 4-20 Two-foot operation ....................................... 4-7
• Management ....................................... 4-29 Two-hand operation ...................3-26, 4-7, 4-10
• Modifying............................................. 4-26
• Saving ................................................. 4-29
Programming mode ................................... 4-10
Protective gear ................................. 1-16, 1-31
U
Upper drive .................................................. 3-9
Upper tool
• Drawing ............................................... 4-28
R Upper tool clamping
R-axis........................................................... 3-7 • Dismantling segment........................... 5-11
Robot operation ........................................... 4-7 • Installing segment ............................... 5-12
Upper tools..........................................3-18, 5-4
• Loading.................................................. 5-4
USB data carrier
• Saving a program ................................ 4-29
• Saving tools ......................................... 4-31
S User.............................................................. 1-6
Safety concept........................................... 3-26 User interface
• Structure .............................................. 4-10
Safety information...................................... 1-29
Safety mode Using Online help....................................... 4-15
• Selecting ............................................. 4-19
Safety-Click® .............................................. 3-23
Setting the program data ........................... 4-33
Setup mode ................................................. 4-7
Speeds......................................................... 3-4 V
• Rapid speed .......................................... 3-4
• Spindle return speed............................. 3-4 V axis ......................................................... 3-10
• Working speed ...................................... 3-4
Step change
• Programming....................................... 4-36
Switch cabinet ............................................. 4-5
Switching off .............................................. 4-14 X
Switching on .............................................. 4-13
X axis ........................................................... 3-7
B561EN08.DOC Index 3
Y Z
Y axis ........................................................... 3-7 Z axis............................................................ 3-7
4 Index B561EN08.DOC

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Operator's manual

TruBend Series 3000

TruBend Series 3000

TRUMPF Werkzeugmaschinen GmbH + Co. KG

This document was compiled by the Technical Documentation of TRUMPF

All rights to this documentation, especially the right of reproduction and

© TRUMPF Werkzeugmaschinen GmbH + Co. KG

TRUMPF Werkzeugmaschinen GmbH + Co. KG is not liable for any errors in

1. For your safety............................................................... 1-3

2. Terminology ................................................................... 1-6

3. Operational safety ......................................................... 1-7

4. Overview of dangers ................................................... 1-25

6. Authorized personnel.................................................. 1-28

7. Safe operation, work safety instructions .................. 1-29

8. Confirmation ................................................................ 1-32

B561EN00.DOC Contents 0-5

Who does what?......................................................................... 2-3

1. Installation site............................................................... 2-4

2. Electrical supply ............................................................ 2-7

3. Compressed air supply ............................................... 2-10

4. Operating material ....................................................... 2-12

5. Transport ...................................................................... 2-13

6. Planning aid ................................................................. 2-17

1. Machine concept............................................................ 3-3

0-6 Contents B561EN00.DOC

3. The most important modules ....................................... 3-8

4. Tools ............................................................................. 3-22

5. The most important options ....................................... 3-24

B561EN00.DOC Contents 0-7

1. Description of the operating elements ........................ 4-3

2. Switching on the machine .......................................... 4-12

3. Switching off the machine .......................................... 4-14

4. Using Online help ........................................................ 4-15

5. Entering letters ............................................................ 4-15

6. Optoelectronic safety devices.................................... 4-16

7. Loading a program ...................................................... 4-20

8. Creating a program...................................................... 4-21

0-8 Contents B561EN00.DOC

10. Programming individual bends.................................. 4-26

11. Creating a tool.............................................................. 4-27

12. Program Management ................................................. 4-29

13. Tool data management................................................ 4-31

14. Changing the language ............................................... 4-33

15. Setting the program data ............................................ 4-33

16. Switching between MSC and ASV ............................. 4-34

17. Bending workpieces.................................................... 4-37

18. Bending workpieces step by step.............................. 4-38

19. Moving axes manually................................................. 4-39

Chapter 5 Setting work

1. Adjusting gauge finger.................................................. 5-3

2. Setting up tools.............................................................. 5-4

B561EN00.DOC Contents 0-9

4. Optoelectronic safety devices.................................... 5-13

1. General guidelines......................................................... 6-3

2. Maintenance overview................................................... 6-4

3. Lubrication ..................................................................... 6-5

4. Hydraulic components ................................................ 6-16

5. Pneumatic components .............................................. 6-18

0-10 Contents B561EN00.DOC

7. Electrical components ................................................ 6-26