b561en trubend

Operator's manual

TruBend Series 3000

Operator's manual

TruBend Series 3000

Edition: 11/2007

Ordering information Please indicate the title of the document, the desired language, and the date of the edition. TRUMPF Werkzeugmaschinen GmbH + Co. KG Technische Dokumentation Johann-Maus-Strae 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: [email protected]

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.

B561EN00.DOC Contents 0-5

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

0-6 Contents B561EN00.DOC

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


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 5-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

4. Optoelectronic safety devices.................................... 5-13 4.1 TRUMPF BendGuard .................................................... 5-13

Dismantling BendGuard ........................................... 5-13 Installing BendGuard ................................................ 5-14 Setting the height of BendGuard .............................. 5-16 Checking the laser beam.......................................... 5-17

4.2 Light curtain ................................................................... 5-18 Aligning transmitter and receiver .............................. 5-18 Checking the function of the light curtain ................. 5-19

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 5.2 Maintenance instructions ............................................... 6-19

Compressed air filter with water separator............... 6-19


6. Mechanical components............................................. 6-21 6.1 Overview........................................................................ 6-21 6.2 Maintenance instructions ............................................... 6-22

Upper and lower tool holders.................................... 6-22 Z axis guide rail......................................................... 6-24 Z axis toothed belt (with optional 4-axes backgauge) ............................................................... 6-24 X axis fixed stop ....................................................... 6-25

7. Electrical components ................................................ 6-26 7.1 Overview........................................................................ 6-26 7.2 Maintenance instructions ............................................... 6-28

Safety switch of the protective covers ...................... 6-28 Failsafe control system PCSS-F............................... 6-29 Electrical cables........................................................ 6-30 Switch cabinet........................................................... 6-31 Optoelectronic safety device .................................... 6-31

Chapter 7 Network card (optional)

Chapter 8 Index

B561EN01.DOC 0BSafety 1-1

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

1-2 0BSafety B561EN01.DOC

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

B561EN01.DOC 1BFor your safety 1-3

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.

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. This operator's manual describes the "completely secured machine" version.

Securing the basic machine

Contents of the operator's manual

1-4 1BFor your safety B561EN01.DOC

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.

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.

Fig. 52396en

B561EN01.DOC 1BFor your safety 1-5

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

1-6 2BTerminology B561EN01.DOC

2. Terminology

... 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. ... is the person in whose premises the machine is installed and operated. ... are the persons responsible for transport, installation, startup, operation, maintenance, including cleaning and elimination of malfunctions on the machine.

Danger zone

The user/owner

Operator/personnel

B561EN01.DOC 3BOperational safety 1-7

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. The machines are designed as standard for operation by one 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.

Loading and removing workpieces manually

1-8 3BOperational safety B561EN01.DOC

The workpieces are correctly positioned if, from the point of view of 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. If the machine is converted to robot loading, the machine's stan-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. Any other form of use is regarded as other than intended. The 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. 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)

The electrical and electronic devices and components used in the 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.

Positioning workpieces correctly

Operating a machine with a robot

No liability for unintended use!

Alterations to the machine

Use the machine only within the industrial sector


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:

... indicates a very serious danger. If not avoided, it could result in death or serious injury. ... indicates a dangerous situation. If not avoided, it could result in serious injury or significant material damage. ... 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:

Caution

Unfiltered oil can destroy the hydraulic system! Warranty claims are rendered void. Use filters with 3 m pores to prefilter new oil.

Danger

Warning

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

Note on freeing trapped persons with the EMERGENCY-UP foot switch

Fig. 32650

Fig. 39136


Signage on the machine in the USA

Dangers related to the operation of the press brake and additional information

Information about the danger zone

Fig. 33155

Fig. 49011


Note that operators should not put their hands between the tools

Notice that the machine is top-heavy

Safety information on operating a press brake

Fig. 33180

Fig. 33181

Fig. 33182


Notice to avoid head injuries 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. Anyone authorized by the user to operate, service and repair the 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. The responsibilities concerning operation, maintenance and repairs must be clearly defined and adhered to in order to avoid any confusion as regards the safety. 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.

Fig. 33183

Instructing personnel

Read the machine documentation

Defining responsibilities

Working safely


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

The user and the persons in charge are under obligation to operate 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. 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. 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. The operator must always make sure nobody is within the danger zone before starting up the machine. 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. 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. Neither the user nor the operator is permitted to dismantle any safety devices or remove them from service.

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.

Only operate the machine if it is in perfect working order

Safe work station

Wear protective clothing

Checking the danger zone

Check the tooling status

Report defects and damage

Checking safety devices and keeping them in working

order


Unless stipulated otherwise, the machine should be switched off at 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.

Procedure in the event of malfunctions or emergencies

If a fault occurs during a machine operating process, the operator 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. If a person's limb gets trapped in the machine. If there is a danger of parts of the body getting caught in the

machine. In all other situations. The machine should be shut down by means of the 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.

Observing the shutdown procedure

EMERGENCY STOP and EMERGENCY-UP

Press the EMERGENCY-UP foot switch

PRESS EMERGENCY STOP

Shut down using the MAIN SWITCH


Using the spare parts and operating materials intended for the machine

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. 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. The instructions for using operating materials (particularly 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.

Use original parts

Liability disclaimer

Instructions for using 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. The machine is equipped with the following safety measures for 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. 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 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. 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.

Safety measures for the danger zone

Optoelectronic safety device

TRUMPF BendGuard

Light curtain


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.

In the two-hand operation, the beam can move down (as far as the mute point) at rapid speed (>10 mm/s). After every bend, the approach to the next position of the 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.

The rear stop moves automatically to the next stop position at the 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.

"Foot operation" mode

"Two-hand operation" operating mode (optional)

Manual increment switching (MSC)

Automatic safety travel speed system (ASV)


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: All CNC-controlled axes are stopped. 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. All CNC-controlled axes 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.

Protective interlock devices


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. The control connection between the robot and the press is on the 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.

During manual repositioning of the gauge fingers, they move to a safe tooling position for the operator in front of the tool level. The operator does not need to reach through the tool level.

Safety control system

Robot switch in switch cabinet

Manual backguage finger adjustment


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. 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.

EMERGENCY STOP

Foot switch EMERGENCY-UP

B561EN01.DOC 4BOverview of dangers 1-25

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 having body parts sheared off.

Working movements of the press beam with upper tool.

Movement of the back-gauge and workpiece.

Vertical tool change. Collision of the backgauge

with upper or lower tools. Stopping and positioning

of the workpieces. Movement of the work-

piece during and after machining.

Risk of injury Operation by trained and instructed personnel.

Wear personal pro-tective gear (work gloves, safety shoes.

Risks due to emission of gasses with high pressure (in case of optional pneumatic tool clamping).

Bursting of pneumatic lines or hoses.


Danger due to falling workpieces. Releasing the workpiece after bending.


Use support brackets. Wear safety shoes.

Hazards due to instability. Tipping over of the machine.

Danger of death, danger of injury

Anchor the machine to the floor.

Use load suspension points for transport, installation, and disassembly of the machine (for load suspension points, see chapter 2 "Installation requirements").

1-26 4BOverview of dangers B561EN01.DOC

Type of hazard Dangerous point Danger Additional precaution

Electrical hazard

Due to electrical contact. Direct contact with parts which are normally live.

Indirect contact with parts which are live due to a malfunction.

Risk of fatal injury Specially trained personnel for maintenance/servicing/repairs.

Hazards due to substances

Contact with or inhaling of toxic fluids, gases, mist or fumes.

Oily compressed air. Lubrication and cleaning

when putting the machine into service.

Health risk Use oil-free compressed air.

Ventilate the workplace sufficiently.

Observe the notes in the operating manual.

Tab. 1-2

B561EN01.DOC 5BWorkplaces 1-27

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. The A-rated equivalent continuous sound pressure level at the workstation of the operating personnel is no higher than 70 dB(A).

Equivalent continuous sound pressure level

1-28 6BAuthorized personnel B561EN01.DOC

6. Authorized personnel

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. Qualified specialists (e.g. trained mechanics). Qualified specialists (e.g. trained mechanics). Qualified specialists (e.g. trained mechanics). Qualified electrician.

Operating the machine

Transporting, installing and removing machines

Machine servicing, maintenance

Checking safety devices

Electrical work

B561EN01.DOC 7BSafe operation, work safety instructions 1-29

7. Safe operation, work safety instructions

Warning

Beam moves downwards. Amputation of body parts possible. Never insert hand between upper and lower tools.

Fig. 25903

1-30 7BSafe operation, work safety instructions B561EN01.DOC

Warning

Workpiece limbs fold upwards during bending and then back again after bending is complete! Risk of injury. Workpiece should be gripped only from the side.

Fig. 25904

Fig. 25905

B561EN01.DOC 7BSafe operation, work safety instructions 1-31

Warning

Workpiece sides fold upwards during bending! Risk of injury. Maintain sufficient distance between yourself and the

workpiece.

Caution

Workpieces having sharp edges! Wear personal protective gear (gloves, safety shoes, safety

glasses).

Warning

Immediate discharge of the beam! Risk of injury due to flying workpieces, bursting hydraulic lines, damage to hydraulic cylinder seals or hydraulic valves. For special applications (e.g. punching, cutting): obtain the

manufacturer's approval.

Observe the bending instructions (e.g. match the sheet size to the die width of the lower tool).

Fig. 25906

1-32 8BConfirmation B561EN01.DOC

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

B561EN02.DOC Installation plans - Version 3 2-1

Chapter 2

Installation conditions

Material number: 0366209

2-2 1BInstallation site - Version 3 B561EN02.DOC

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


Who does what?

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. 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.

Customer

TRUMPF Service


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

The floor should be as even as possible. Height variation, maximum 10 mm/0.39 in. 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.).

20

Evenness of the installation surface

Installation surface


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. If the machine is installed on a ceiling plate or free-span base 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

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 the front

[kg] 2070 2880 4900

Weight on each support point at the rear

[kg] 630 1270 1700

Weight support per base on a surface area of ...

[mm2] 160 x 200 160 x 200 160 x 200

Elastic base plate

Ceiling plate/ free span base plate

Structural stress analysis

Tab. 2-1


1.4 Ambient conditions

Permissible ambient temperatures for the operation of the machines: +10C/+50F to +40C/+104F. According to NFPA 79, the maximum temperature in the USA

and Canada is 40C/104F. Permissible temperature range for the control system during 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. 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.

Ambient temperature of the machine

Ambient conditions for the control system

Hydraulic system


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. Note The NEC applies only to Canada and the USA.

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. Power supply lines in ungrounded power supply systems with delta 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).

NEC conditions

Grounding

Grounded power supply with star connection

2-8 2BElectrical supply - Version 3 B561EN02.DOC

2.2 Connected loads, fuse protection and frequency

Machines may be connected only by qualified specialists. 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

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)

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 90C/194F. 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.

Connected loads

Tab. 2-2

Connecting cables

Tab. 2-3

NEC conditions


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. If several machines are to be connected to the network, a per-sonnel switch (network distributor) is necessary. The network 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).

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.

Establishing an alternating current supply for the

personnel switch

Provision of power supply

2-10 3BCompressed air supply - Version 3 B561EN02.DOC

3. Compressed air supply

Note Compressed air supply is required only in machines with pneumatic tool clamping (optional). The compressed air connection may be flexible or constructed

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.

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 flow according to ISO 1217 or DIN 1945)

approx. 0.1 m3/h

Length of the connecting line No limit

Property Requirement Quality

class (ISO 8573-1)

Recommendation

Condensate-free

Cooled to +7C/+44.6F (pressure dew point)

5 Cold dryer

Dust-free Max. particle size: 15 m Max. particle density: 8 mg/Nm3

4 Air filter in front of the system

Oil-free Max. oil content: 5 mg Nm3

4 Compressing compressors as low-oil or oil-free as possible

Requirements for the compressed air network

Connected loads

Tab. 2-4

Properties of the compressed air at the tapping point

Tab. 2-5


A maintenance unit (filter regulator B07) is mounted on the machines:

TruBend Series 3000 pneumatic system maintenance unit Connecting a suitable compressor to the cold dryer and microfilter combination to the machine: Maximum compressor-to-machine distance: 50 m

Min. nominal diameter of pipelines 1"

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. Condensation water can form with distances >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 for the use of compressors, cold dryers and microfilter combinations can be obtained upon request.

Maintenance unit

Fig. 44597

Insufficient compressed air network?

Tab. 2-6

Distance to the compressor >50 m

Additional recommendations

2-12 4BOperating material - Version 3 B561EN02.DOC

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 m. 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).

TruBend 3066 TruBend 3120 TruBend 3180

Oil quantity [l] 100 200 250

Oil quantity

Tab. 2-7


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. TruBend 3066 3120 3180

Length [mm] 2600 3600 4610

Width [mm] 1750 1750 2000

Height [mm] 2330 2330 2330

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

2-14 5BTransport - Version 3 B561EN02.DOC

5.2 Unloading the machine, transporting it to the installation site

Warning

The center of gravity of the machine is very far from the front. The machine can easily tip over. 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.


Unloading and transporting the machine

Additional equipment, tools, material Form A (DIN 82101) shackles. Use two Form A (DIN 82101) shackles per machine:

Form and dimensions of shackle TruBend 3066/3120 3180

Permissible loading [kN] 120 160

Bolt diameter ["] 2 2.4

d1 [mm] 47 52

d4 [mm] 52 60

h1 [mm] 158 185

Main dimensions

b1 [mm] 73 81

Fig. 52814

Tab. 2-9

2-16 5BTransport - Version 3 B561EN02.DOC

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

D diameter of the suspension

holes x distance of the suspension holes

to the upper edge of the machine

Location of suspension holes TruBend 3066 3120 3180

Diameter D [mm] 60 60 70

Distance x to the upper edge of the machine

[mm] 100 100 105

Thickness of the side plate

[mm] 40 60 70

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:

Transport the machine on armored rollers. or Transport machine using a gantry crane with sufficient

carrying capacity.

Fig. 52190

Tab. 2-10


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 machine

Planning criteria Measures

8 weeks Personnel and training course

Appoint a member of staff to be responsible for preparations for the delivery of the machine. Select operating personnel, maintenance personnel, and programmers. Set dates for training courses.

8 weeks Installation site

20

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 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 electricians

Establish electrical connections to the system.

30 31

Tab. 2-11

2-18 6BPlanning aid - Version 3 B561EN02.DOC

B561EN03.DOC 0BDescription 3-1

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 4-axes backgauge (optional) .................................... 3-17

3-2 0BDescription B561EN03.DOC

5-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

B561EN03.DOC 1BMachine concept 3-3

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.

3-4 2BTechnical specifications B561EN03.DOC

2. Technical specifications

2.1 Machines

TruBend 3066 3120 3180

Press force [kN] 660 1200 1800 Services

Length of bend [mm] 2080 3110 4140

Weight [kg] 4900 7700 13200

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

Machine measurements

Work table width [mm] 80 100 150

Installation height [mm] 470 470 470

Tool installation height (TRUMPF) [mm] 347 347 347

Working height

Working height with lower tool 100 mm

[mm] 1000 1000 1000

Y rapid speed [mm/s] 200 115 200

With CE [mm/s] 10 10 10 Y working speed

Without CE

[mm/s] 20 12 15

Y axis speeds

Y spindle return speed [mm/s] 180 135 180

Version - CNC-controlled

CNC-controlled

CNC-controlled

Stroke [mm] 200 200 200

Positioning accuracy [mm] 0.01 0.01 0.01 Inclined position [mm] 3.0 3.0 3.0

Y axis (beam)

Max. stop range X [mm] 880 880 880

Electric [kW] 11 11 18.5 Connected loads

Quantity of hydraulic oil [l] 100 200 250

Tab. 3-1

B561EN03.DOC 2BTechnical specifications 3-5

Installation height: Throat: Tool installation height:

470 mm 432 mm 347 mm

Fig. 52431

3-6 2BTechnical specifications B561EN03.DOC

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

Version CNC-controlled

Traverse path [mm] 600

Positioning accuracy [mm] 0.05

X axis

Travel speed [mm/s] 500




X5 axis (optional)

Travel speed [mm/s] 500




R axis

Travel speed [mm] 200

Z axis Version Manual or CNC-controlled

Tab. 3-2

B561EN03.DOC 2BTechnical specifications 3-7

2.3 Machine axes

Axis Description TruBend Series 3000

R axis Gauge finger height adjustment CNC-controlled

X axis Backgauge traverse path forwards and backwards

CNC-controlled

Y axis Stroke and inclined position of the beam

CNC-controlled

Z axis Left and right gauge finger displacement

Manual or CNC-controlled

Fig. 52440

Tab. 3-3

3-8 3BThe most important modules B561EN03.DOC

3. The most important modules

6

78

9

10

1

4

2

3

5

1 Upper drive 2 Control system 3 Switch cabinet (left-hand side) 4 Support brackets

5 Press beam 6 Upper tool holder 7 Backgauge 8 Lower tool holder

9 Crowning 10 Machine frame

Fig. 52441

B561EN03.DOC 3BThe most important modules 3-9

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. 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.

Inclined position of the beam


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 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. 29748

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 12 1 Crowning slot with wedge

system 2 Hydraulic crowning

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.

7

8

9101112

3

6

4

1

5

2

1 LCD display/screen 2 Softkeys S1 to S8 3 HELP 4 EMERGENCY STOP impact

button 5 Alphanumeric keyboard with

ENTER 6 Touch Pad

7 END 8 Cursor keys 9 Jog button 10 Operating mode keys 11 START 12 STOP

Operating elements on the control panel

Fig. 52434


T3000 VA control system

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. 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).

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. Every bend is individually processed in the step-by-step operation. Every bend must be restarted using START.

Help, wherever it is required

Programming

Production

Step-by-step operation


T3000 VA

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

Technical specification for the control system

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

button 2 Indicator lamp

3 EMERGENCY-UP foot switch 4 BEAM DOWN foot switch

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). In case of a collision, the ideally hinged standard gauge fingers flip backwards. This prevents damage to bending parts and to the gauge finger. The gauge fingers can be moved 20 mm in front of the tool plane for repositioning. Because of this, the operator does not have to reach through the tool plane unassisted or using an auxiliary tool.

Backgauge system

Upward folding gauge fingers

Safe shifting of the gauge fingers

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)

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.

Extended backguage concept


3.8 Tool clamping

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). 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.

Upper tool holder

Lower tool holder


Manual tool clamping

The manual tool clamping consists of individual segments that can be opened and closed with two hexagonal socket screws.

The manual tool clamping for lower tools consists of individual segments that can be opened and closed with three hexagonal socket screws.

Upper tool clamping

Fig. 52973

Lower tool holder

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. The required clamping power for the upper tools is infinitely adjustable manually.

Clamping power is infinitely adjustable

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)

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 usi

b561en trubend

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