Operator's Manual

Operator's manual
D70
Operator's manual
D70
Original operator's manual

Edition 2019-03
Order Information Please specify when ordering this document:
Operator's manual
D70
Edition 2019-03
Document number 21-01-29-CRen
TRUMPF Laser GmbH

Address for orders Vertrieb
Aichhalder Straße 39
78713 Schramberg
Fon: +49 7422 515 - 0
Fax: +49 7422 515 - 436
Internet: http://www.trumpf-laser.com
E-Mail: info@de.trumpf-laser.com
TRUMPF Laser GmbH

Address for service Technischer Kundendienst
Aichhalder Straße 39
D-78713 Schramberg
Fon: +49 7156 303 - 37 444
Fax: +49 7422 515 - 148
Internet: http://www.trumpf-laser.com
E-Mail: service.tls@de.trumpf.com
E-Mail: spareparts.tls@de.trumpf.com
© TRUMPF Laser GmbH

Before you proceed ...
What do the operating These operating instructions contain important information on

instructions contain? the focusing optics, its functions, the necessary adjustment work
and upkeep. This information will help you operate the laser
product safely, avoid any risks, reduce service costs and break-
down times and increase its reliability and service life.
Other regulations In addition to the Operator's manual, observe the regional regu-
lations regarding accident prevention, laser safety, and environ-
mental protection.
Who is the operator's The laser product Operator's manual must be read and
manual for? observed by every person who is commissioned with working on
the laser product.
Examples of work on the laser product:

■ Operation
■ Maintenance
■ Transport
Documentation for further ■ Operator's manual for the laser device.

reference ■ TruControl 1000 software manual.
■ Interface descriptions.
■ Dimensional drawings.
■ Data sheets.
■ Acceptance protocol.
■ Operating instructions for illumination module D70 when
operated with camera.
■ Operator's manual for programmable motor-driven focusing.
■ Operator's manual for rotary module for shield gas guidance.
■ Operator's manual for a CCD camera which is operated on
focusing optics.
21-01-29-CRen 2019-03 Before you proceed ... I

II Before you proceed ... 2019-03 21-01-29-CRen
Table of contents
Chapter 1 Safety
1 For your safety 1‐3
2 Warning instructions 1‐4
3 Terms 1‐5
4 Hazards 1‐8
4.1 Laser light 1‐8
4.2 Gases, aerosols, dusts 1‐9
4.3 Thermal energy 1‐10
Fire, explosion 1‐10
Temperature of the workpiece 1‐10
Hot surfaces on the focusing optics 1‐10
4.4 Noise 1‐11
5 Safety of the laser product 1‐12

5.1 Laser beam emission openings 1‐12
5.2 EMERGENCY STOP push-button 1‐16
5.3 Labels and warning signs 1‐16
Labels on the focusing optics 1‐17
Labels in the range of the focusing optics 1‐17
6 Measures of the user 1‐19

6.1 Intended use 1‐19
6.2 Technical measures 1‐20
6.3 Organizational measures 1‐21
6.4 Observing standards and regulations 1‐22
6.5 Behavior in certain operating stages 1‐22
6.6 Behavior in case of emergency 1‐23
6.7 Selecting and qualifying personnel 1‐24
6.8 Instructing the personnel 1‐24
6.9 Wearing personal safety equipment 1‐25
21-01-29-CRen 2019-03 Table of contents 0‐1

Chapter 2 Assembly and installation
Assembly and installation 2‐3
1 Integration into a system environment 2‐4

1.1 Fastening 2‐4
1.2 Clearances 2‐7
1.3 Example 2‐8
2 Installation 2‐12
2.1 Overview of the connections 2‐12
2.2 Principles, general rules 2‐13
2.3 Safe combination of laser device, laser light 2‐14
cable and focusing optics
Characteristics of safe combinations 2‐14
Dangers due to impermissible combina- 2‐15
tions
Information required to assess the safety 2‐16
of a combination
2.4 Connection of the laser light cable (LLK) 2‐18
Connecting the laser light cable to the 2‐21
focusing optics
2.5 Connections for cooling unit 2‐25
2.6 Connections for lens with exhauster 2‐29
Commissioning of a lens with exhauster 2‐29
2.7 Connections on the crossjet 2‐31
2.8 Connection for cutting optics 2‐36
2.9 Connection for proximity switch 2‐37
3 Ambient conditions 2‐39

3.1 Determining the necessary cooling water tem- 2‐40
perature
4 Using shielding gas 2‐41

4.1 Gases during laser welding 2‐41
4.2 What is shielding gas used for? 2‐41
4.3 Shielding gases 2‐42
Nitrogen (N2) 2‐43
Argon (Ar) 2‐43
0‐2 Table of contents 2019-03 21-01-29-CRen

Helium (He) 2‐43
Recommendations 2‐43
4.4 Shielding gas supply 2‐44
Single tube 2‐45
Multiple tube 2‐46
Conical nozzle 2‐48
Other methods 2‐50
4.5 Arrangement of the shielding gas nozzles 2‐50
Pulsed lasers 2‐51
cw lasers 2‐52
Welding at edges 2‐53
4.6 Dosing shielding gas 2‐53
4.7 Effect of the shielding gas 2‐56
Chapter 3 Description
1 Models and options 3‐3

1.1 Minimum configuration 3‐3
1.2 Available modules 3‐4
2 Components 3‐7
2.1 Focusing optics module overview 3‐7
2.2 Requirements 3‐10
2.3 Plug receptacle 3‐12
2.4 Protective sleeve 3‐13
2.5 Collimation 3‐14
2.6 Motor-driven focal control (analog) 3‐16
2.7 Programmable motor-driven focus setting pro- 3‐17
cedure (PMF)
2.8 Pivot joint 3‐18
2.9 Dual focus optics 3‐18
Dual focus optics with fixed splitting ratio 3‐19
and fixed distance between the focal
points
Dual focus optics with variable splitting 3‐21
ratio and fixed distance between the focal
points
and variable distance between the focal
points

2.10 Connecting piece 3‐25
2.11 Observation optics 3‐27
2.12 Illumination module 3‐31
2.13 Interface for sensor module 3‐32
2.14 Lenses for welding 3‐32
Lens with exhauster 3‐38
Crossjet 3‐39
2.15 Line laser 3‐43
2.16 Compensation cassette 3‐44
2.17 Cutting optics 3‐46
2.18 Protective glass monitoring 3‐48
2.19 Connection plates 3‐49
2.20 Magnetic coupling 3‐51
2.21 Focusing optics examples 3‐52
3 Functional description 3‐59

3.1 Beam guideway of the laser light 3‐59
3.2 Beam guideway in the observation optics 3‐65
3.3 Connection to the laser device 3‐67
Chapter 4 Adjustment work
General notes on adjustment work 4‐3
1 Aligning the focusing optics 4‐4

1.1 Aligning the focusing optics 4‐4
2 Adjusting the focal position 4‐5

2.1 Setting zero position 4‐6
2.2 Taking objects out of the beam guideway 4‐6
2.3 Adjusting the working distance 4‐7
Determining the focal position with the 4‐9
working laser
Measuring the working distance 4‐10
Adjusting the focal position by means of 4‐12
the line laser
2.4 Adjusting the distance caliper 4‐12
2.5 Adjusting the line laser 4‐14

2.6 Defocusing the focusing optics 4‐16
Defocusing the focusing optics 4‐18
2.7 Adjusting the focusing optics in the x-y direc- 4‐19
tion.
Adjusting the focusing optics, zero position 4‐20
Adjusting the focusing optics to a new 4‐20
workpiece
3 Adjusting the dual focus optics 4‐21

3.1 Dual focus optics with fixed splitting ratio 4‐21
and fixed distance between the focal points
Turning the focal points around the center 4‐21
axis
Adjusting the splitting ratio 4‐21
3.2 Dual focus optics with variable splitting ratio 4‐22
Turning the focal point around the center 4‐23
line
points
Adjusting the distance between the focal 4‐26
points
axis
4 Adjusting the observation devices 4‐29

4.1 Adjusting the picture sharpness of eyepiece 4‐29
or camera
4.2 Adjusting the cross hairs 4‐31
4.3 Adjusting the illumination 4‐32
Chapter 5 Maintenance
1 General notes 5‐3
2 Material 5‐5
2.1 Wearing parts 5‐5

2.2 Optics cleaning kit 5‐6
2.3 Consumables 5‐7
2.4 Disposal 5‐7
2.5 Tools and additional equipment 5‐8
3 Laser light cable (LLK) 5‐10

3.1 Disconnecting the LLK from the focusing 5‐10
optics
4 Welding optics 5‐13

4.1 Cleaning the protective glass in the lens pro- 5‐13
tection
4.2 Changing the protective glass of the lens pro- 5‐14
tection
4.3 Cleaning the protective glass in the protec- 5‐16
tive glass cassette
4.4 Replacing the protective glass of the protec- 5‐18
tive glass cassette (protective glass cassette
NU (NU=groove ring), starting from Septem-
ber 2016)
tive glass cassette
4.6 Changing the additional protective glass 5‐22
4.7 Replacing the lens along with the cassette 5‐25
module
4.8 Changing a lens without cooling ring 5‐28
4.9 Changing a lens with a cooling ring 5‐30
4.10 Cleaning the splash guard 5‐32
4.11 Cleaning the shielding gas supply 5‐33
4.12 Changing the tubes of the multiple tube 5‐34
5 Welding lens for lens with exhauster 5‐37

5.1 Clean or replace safety glass 5‐37
5.2 Cleaning the whole lens protection 5‐41
6 Compensation lens of the compensation 5‐44

cassette
6.1 Replacing the compensation lens of the com- 5‐44
pensation cassette
7 Line laser 5‐46

7.1 Replacing the line laser 5‐46

8 Cutting optics 5‐48
8.2 Adjusting a cutting optics equipped with 5‐53
observation optics
Aligning the cross hairs with the beam 5‐53
center
Adjusting the x-y direction 5‐53
Adjusting the z direction 5‐54
8.3 Adjusting a cutting optics without observation 5‐56
optics
Chapter 6 Eliminating faults
1 Conduct in case of malfunctions 6‐2

1.1 Step-by-step procedure: 6‐2
1.2 Troubleshooting 6‐2
1.3 Malfunctions, possible causes and measures 6‐4
2 Observing messages 6‐10
3 Informing the service department 6‐11

Chapter 1
Safety
1 For your safety 1‐3
2 Warning instructions 1‐4
3 Terms 1‐5
4 Hazards 1‐8
4.1 Laser light 1‐8
4.2 Gases, aerosols, dusts 1‐9
4.3 Thermal energy 1‐10
Fire, explosion 1‐10
Temperature of the workpiece 1‐10
Hot surfaces on the focusing optics 1‐10
4.4 Noise 1‐11
5 Safety of the laser product 1‐12

5.1 Laser beam emission openings 1‐12
21-01-29-CRen 2019-03 Safety 1‐1

5.2 EMERGENCY STOP push-button 1‐16
5.3 Labels and warning signs 1‐16
Labels on the focusing optics 1‐17
Labels in the range of the focusing optics 1‐17
6 Measures of the user 1‐19

6.1 Intended use 1‐19
6.2 Technical measures 1‐20
6.3 Organizational measures 1‐21
6.4 Observing standards and regulations 1‐22
6.5 Behavior in certain operating stages 1‐22
6.6 Behavior in case of emergency 1‐23
6.7 Selecting and qualifying personnel 1‐24
6.8 Instructing the personnel 1‐24
6.9 Wearing personal safety equipment 1‐25
1‐2 Safety 2019-03 21-01-29-CRen

1. For your safety
Safety is essential This chapter contains important hints for a safe operation of the
laser product. Read the hints carefully before putting the laser
product into operation.
Chapter safety This chapter summarizes information that the operator must
know to ensure a safe operation of the laser device.
Information on the following factors is indicated:

■ Hazards that may arise from the laser product.
■ Devices and measures which we have already realized as
the manufacturer to ensure a safe operation of the laser
product.
■ Instructions that the user must realize in order to operate
the laser product safely in the work environment and to pro-
tect the health of persons.
Hazards and warning hints The operator's manual contains descriptions and instructions for
the efficient use of the laser product. When hazards may arise,
the instructions are preceded by warning hints warning of the
consequences.
Note
The operator must permantently keep the operator's manual at
the place where the laser product is used.
21-01-29-CRen 2019-03 For your safety 1‐3

2. Warning instructions
A warning instruction is information that:

■ Names the type and source of a danger.
■ Indicates possible consequences in case the danger is not
avoided.
■ Gives instructions for how to avoid any damage.
One of the signal words "Danger", "Warning", "Caution", or
"Attention" indicates the severity of the possible consequences
in case the instructions are not observed.
"Danger" warns against a great danger. If not avoided, it leads
to death or serious injuries.
"Warning" warns against a danger that may cause medium or
serious injuries with permanent damage.
"Caution" warns against a danger that may cause light or
medium injuries without permanent damage.
"Attention" warns against possible material damage.
Example of a warning instruction:
Eyes and skin may be exposed to laser radiation if the

WARNING laser light is not placed under a protective cover!
Laser light can burn the skin. Direct or scattered laser light
can permanently damage your eyes.
Ø Take the necessary protective measures as specified below,
depending on the laser class.
It is absolutely necessary to observe and follow the warning

instructions!
1‐4 Warning instructions 2019-03 21-01-29-CRen

3. Terms
Laser product Laser products include devices, systems or components used

for generating, transmitting and using laser light.
TRUMPF products summarized under the term "laser product"

include:
■ Lasers (beam sources)
■ Laser machines
■ Laser workstations
■ Laser devices
■ Laser light cables
■ Focusing optics
Laser light Laser light is electromagnetic radiation with wavelengths from

100 nm to 1 mm produced as the result of controlled stimulated
emission.
Laser is an acronym, short for: Light Amplification by Stimulated
Emission of Radiation.
Laser The term "Laser" summarizes all components directly used for
generating laser light:
■ Resonator, comprising rear mirror and output coupling mirror
■ Laser material
■ Pump source
Other components of lasers might include:

■ Modulators
■ Q-switch
■ Converter for generating other wavelengths
With certain forms of lasers, the components mentioned above
can be integrated as structures in a basic material.
Examples:
Rear mirror and output coupling mirror:

■ in fiber lasers as Bragg gratings
■ in diode lasers as surfaces in semiconductor crystals.
Laser machine Laser machines are machines the main purpose of which is to
weld or cut material with laser light or to process it in any other
way. In laser machines, movements of the workpieces and focus-
ing optics are mainly controlled automatically.
Laser workstation Laser workstations are facilities at which workpieces are mainly
processed manually using laser light.
21-01-29-CRen 2019-03 Terms 1‐5

Laser device Laser devices include all components required for generating
laser light.
Laser device components include:

■ Laser with pump source
■ Energy supply for the pump source, e.g. diode power supply,
lamp power supply
■ Control
■ Cooling unit
Depending on the type and maximum power of the laser device,

it may have other components, such as:
■ Additional components in the mains distribution
■ Cabinet cooler
■ Air cleaner or recirculating air dryer system
■ Gas purging unit
Pump light cable The pump light cable is a flexible connection element between
supply unit and laser head. The pump light is guided in a light
guide from the pump diode to the laser head. Around the light
guide there are different devices to avoid uncontrolled exit of
laser light and to protect the light guide.
Laser light cable The laser light cable is a flexible connecting element between
laser device and focusing optics. The laser light is guided from
the laser to the focusing optics in a light guide. For ultrashort
pulse lasers, only so-called hollow-core fibers are suitable due
to the high peak power, where the intensive laser pulse is not
conducted in glass, but in a vacuum, air or another filling gas.
The light guide is surrounded by several devices that prevent an
uncontrolled escape of laser light and protect the light guide.
Focusing optics Focusing optics are optical assemblies. Their main function is to
form the laser beam so that it achieves its maximum power den-
sity at a defined point, the focal point.
In the reflective focusing optics (RFO), the conical laser beam
coming out of the laser light cable hits the focusing mirror,
which guides the laser beam through the exit port and merges it
in the focal point.
The programmable focusing optics (PFO) includes one or two
scanner mirrors which allow the laser beam to be guided over a
processing field. It is thus possible to produce, for example,
welding seams without moving the focusing optics and the work-
piece.
The distance of the focal point from a certain edge or surface of
the focusing optics is called working distance. The working dis-
tance of the focusing optics determines the distance in which
the workpieces must be positioned so that they can be proc-
essed with the laser.
1‐6 Terms 2019-03 21-01-29-CRen

Laser beam guidance The laser beam guidance deflects the output radiation of the
laser to the workpiece.
Safety circuit A safety circuit is an electric circuit for monitoring protective cov-
ers and doors of laser protective casings and cabins. When the
contacts are looped in, the safety circuit should always be
closed when all monitored covers and doors are closed.
When a contact interrupts the safety circuit because a door is
opened, for example, laser light emission is immediately stopped.
The safety circuit, as a central shutter of a laser device, stops
emission of laser lights on all light paths of the laser device.
The safety circuit of just one light path only stops light emis-
sion on this light path. Laser light can still be emitted on the
other light paths if these safety circuits are closed.
21-01-29-CRen 2019-03 Terms 1‐7

4. Hazards
The laser product has been built in accordance with state-of-the-

art standards and the recognized safety rules. However, it might
cause hazards for persons or material property during use. If
you do not observe the accident prevention regulations, these
hazards may result in damage.
The following overview indicates the possible hazards that might
be caused by your laser product.
■ It indicates how TRUMPF has reduced the risk by applying

constructive measures.
■ You, as the user, can ensure safe operation of the laser
product by taking additional measures during its use.
4.1 Laser light
Solid state lasers generate laser light in the near infrared spec-
tral range (900 nm – 1250 nm). Using converters, the laser light
can also be produced in the visible range (400 - 700 nm) or in
the ultraviolet spectral region (< 400 nm).
Laser light may be hazardous to eyes and skin.
Depending on the severity of the danger, laser products are clas-
sified in laser classes.
The classification of the laser product in laser classes is defined
internationally in the EN 60825-1 and IEC 60825 standards.
The meaning of the laser classes is described briefly below. The
precise definition listing limit values can be found in the stand-
ards stated above.
Class 1 Class 1 means that the laser light of this laser product is not
dangerous in standard operation.
The laser device is classified as class 1M (acc. to EN 60825-1)
if there may be a risk when observing laser light through optical
instruments.
Class 2 A class 2 laser product only emits in the visible spectral region
(400 - 700 nm). A brief exposure does not involve any risk.
Deliberate staring in the beam might be dangerous for your
eyes. Active reactions are sufficient to protect your eyes against
damage: Avert your eyes, move your head or close your eyes.
The laser device is classified as class 2M (acc. to EN 60825-1)
if there may be a risk when observing laser light through optical
instruments.
1‐8 Hazards 2019-03 21-01-29-CRen

Class 3 Class 3 is subdivided into class 3R and class 3B acc. to EN
60825-1. A previously existing restriction of class 3 to certain
spectral ranges no longer exists.
Class 3R laser products exceed the limits of class 2. In most
cases the risk is low. The risk of injury increases with the time
of exposure. A deliberate irradiation of your eyes is dangerous.
Class 3B laser products are normally dangerous when you look
directly into the beam. The observation of diffuse reflections is
usually not dangerous. Class 3B laser products the power of
which almost reaches that of class 4 might produce light skin
injuries; they might also ignite inflammable material.
Class 4 Exposure of the eye or skin to class 4 laser products is danger-

ous. Even diffuse radiation (scattered laser light) can be danger-
ous. Class 4 laser light can ignite inflammable material and
make explosive mixtures explode.
4.2 Gases, aerosols, dusts
When workpieces are processed, gases, aerosols or dusts can

be produced; these are dangerous to health. The biggest risk is
caused when the substances enter your respiratory tract. But
even contact with your skin or mucous membranes in your
mouth, nose or eyes can be dangerous.
Dust:
Solid particles > 1 µm.
Aerosols:
Gases with finely distributed solid or liquid particles < 1 µm.
Some escaping substances may cause cancer. The cancer risk
depends mainly on the material of the workpieces and the emit-
ted quantity.
Carcinogenic substances include

■ beryllium compounds
■ zinc chromates
The emitted quantity depends on:

■ the type of material.
■ the speed.
■ the laser power.
■ the cutting gas pressure, if applicable.
21-01-29-CRen 2019-03 Hazards 1‐9

4.3 Thermal energy
Fire, explosion
Class 3B or 4 laser light may cause fires if it ignites inflammable

material.
If there is a potentially explosive mixture of gases or aerosols
(e.g. oxyhydrogen, wood or carbon dust) in the air, a laser
beam might cause an explosion, even if it does not hit solid
material with a high power density.
Temperature of the workpiece
Due to the processing by means of the laser beam, the work-

piece may be heated up. The degree of heating depends on the
material of the workpiece and the energy given off by the laser
beam to the workpiece during processing.
Risk of burns when touching the hot workpiece

WARNING
This may result in skin injuries.
Ø Remove hot workpieces using an appropriate tool.
Ø Wear protective gloves, if necessary.
Hot surfaces on the focusing optics
Due to reflections of laser light on the workpiece, the underside

of the focusing optics may become very hot. Misadjusted or
soiled components may also cause the heating. The tempera-
ture can reach values that may burn the skin in case of a con-
tact.
Hot surfaces on the bottom side of the focusing optics

CAUTION may burn your skin.
Ø Avoid contact with hot surfaces.
Ø Let the focusing optics cool down before carrying out main-
tenance or cleaning work.
1‐10 Hazards 2019-03 21-01-29-CRen

4.4 Noise
Focusing optics The use of focusing optics in conjunction with lasers and assist
gas produces noise.
Sources of noise in the area of the focusing optics include:

■ Material that evaporates as a result of the exposure to laser
light.
■ Cutting gas or shielding gas passed to the processing point.
■ Compressed air coming out of the crossjet.
During laser welding, compressed air comes out of a nozzle,
called crossjet, transversely to the direction of the laser beam.
If a crossjet is present, it is often the biggest source of noise.
Measurements have given values > 90 dB(A).
High noise level when operating a focusing optics,

WARNING especially when using a crossjet!
Noise can result in permanent ear damage and other
unfavorable consequences to health, especially upon
prolonged exposure.
Ø Surround the processing point with a protective cover that is
sufficiently silencing.
Ø Wear ear protection if the noise levels are high.
Ø Operate the focusing optics only with the silencing protec-
tive cover closed, if possible.
The room in which a focusing optics is operated should have

the following characteristics:
■ The processing point should be as far away as possible
from places where people stay permanently.
■ Walls and devices are particularly good absorbers of noise.
■ The areas that are at risk from noise are labeled.
■ Ear protection devices are available in sufficient numbers.
21-01-29-CRen 2019-03 Hazards 1‐11

5. Safety of the laser product
5.1 Laser beam emission openings
The following figures show examples for focusing optics indicat-

ing the laser beam emission opening (arrow).
0030-02-T
Laser beam exit port at focusing optics with welding lens Fig. 1-1
1‐12 Safety of the laser product 2019-03 21-01-29-CRen

Laser beam exit port at focusing optics with cassette mod- Fig. 1-2
ule and Crossjet TL
0030-03-T
Laser beam exit port at a cutting optics Fig. 1-3
21-01-29-CRen 2019-03 Safety of the laser product 1‐13

0030-04-T
Laser beam exit port at a lens with exhauster Fig. 1-4
0030-05-T
Laser beam exit port at the focusing optics with crossjet Fig. 1-5
Focusing optics are composed of modules according to the

requirements of the application. Their appearance may differ
from the appearance shown in the figures. It is possible that sev-
eral laser light cables and focusing optics are connected to one
laser device. The laser light is emitted from the focusing optics
lenses in any case.
Laser light cannot be emitted from other places of the laser
device if all protective covers are closed.

Eyes and skin may be exposed to laser radiation if the
WARNING laser light is not placed under a protective cover!
Laser light can burn the skin. Direct or scattered laser light
can permanently damage your eyes.
Ø In general, install the focusing optics and the processing
spot in a protective housing or below a protective cover so
that no laser light may be emitted during the production
operation.
Basically, the protective housing or the protective cover
must completely surround the laser beam path, the focusing
optics and the processing spot and be designed in such a
way that the accessible laser light is below the limit value of
laser class 1 (according to EN 60825-1).
If protective housing or protective cover are not possible,
the laser product falls into the category of laser class 4. In
this case, all required measures have to be taken according
to EN 60825 (e.g. labels, signalization, access limitation).
Ø Monitor the protective housing or protective cover by means
of a safety circuit.
Ø Wear laser safety glasses which are adapted to the wave-
length of the laser light (see information labels) and cover
the long-wave Raman radiation as well.
Ø Mark dangerous areas and organize access limitations.
Ø Instruct potentially endangered persons.
Wavelengths ■ Laser light for material processing: 890 nm - 1064 nm.

The wavelength range optimized for the lenses of the focus-
ing optics is indicated on the adhesive label attached to the
focusing optics.
■ Pilot laser and line laser: 630 nm - 680 nm.
Note
If the focusing optics is optimized for a certain wavelength, an
adhesive label indicating this wavelength is attached to the
focusing optics. The focusing optics must not be operated with
another wavelength. Otherwise the focusing optics can only be
used in a small range (1030 nm to 1070 nm).
Laser classes Device, component Laserklasse

Laser device with closed hood 1
Laser device with open hood 4
Laser light cables 1
Focusing optics under a closed protective cover (outside 1
protective cover)
Focusing optics under a closed protective cover (inside 4
protective cover)
Focusing optics without protective cover 4
Laser workstation with closed hood. 1

Laser classes Device, component Laserklasse
Laser workstation with open hood. 4
Pilot laser at the exit port (switch, deflection) 3R
Pilot laser at the exit of the focusing optics 2
Tab. 1-1
5.2 EMERGENCY STOP push-button
TRUMPF recommends the provision of an additional EMER-

GENCY STOP push-button at the workplace of the focusing
optics. For further information see the interface description of
the laser device.
5.3 Labels and warning signs
Note
Observe the instructions on the labels. Keep the labels in a
readable condition.

Labels on the focusing optics
2
3
0030-06-T
1 Label: Serial number of the 3 Focal length identification of
focusing optics the lens
2 Label: Identification number of
the focusing optics
Labels on the focusing optics D70 Fig. 1-6
Labels in the range of the focusing optics
Labels and warning signs, attached in the area of the focusing

optics, are described in this section.
The invitation to wear an ear protection needs only be placed
when the focusing optics is equipped with a Crossjet.
Warning of dangerous laser radiation Fig. 1-7

Warning of dangerous laser radiation Fig. 1-8
Request to wear ear protection Fig. 1-9
The labels are adhesive labels with removable protective film.

The labels have not yet been attached in the area of the focus-
ing options as, at the time of delivery, it is usually not known
how the workstation the focusing optics is to be fitted to is set
up.
Mandatory marking As the operator of the laser device you are obliged to attach the
labels near the focusing optics, so that they can be seen by the
persons staying within this area.

6. Measures of the user
6.1 Intended use
The focusing optics is intended exclusively for processing work-

pieces made of solid metals or metal alloys.
The focusing optics can be operated within different wavelength
spectrums. The wavelength spectrum, for which the optical ele-
ments of the focusing optics are optimized, is indicated on the
adhesive label attached to the focusing optics.
The wavelength spectrum depends on the laser device to which
the focusing optics are connected.
Note
When the focusing optics is optimized for a certain wavelength,
an adhesive label indicating this wavelength is attached on the
focusing optics. Then the focusing optics must not be operated
with any other wavelength. Otherwise the focusing optics can
only be used in a small range (1030 nm to 1070 nm).
TRUMPF
ct-00272
Cube 0° with adhesive label Fig. 1-10
Note
Some focusing optics may be operated only in combination with
drill laser devices.
This is indicated on the dimensional drawing of the respective
focusing optics.
21-01-29-CRen 2019-03 Measures of the user 1‐19

Intended use also includes the following:
■ observing the instructions set out in this operating manual.
■ carrying out necessary inspections and maintenance work.
Exception The focusing optics is not designed for:

■ use with other wavelengths than those indicated on the
adhesive label.
■ for processing metals or metal alloys in connection with flam-
mable or explosive materials (examples: containers filled
with combustible gas or fuel, ammunition).
■ use in atmospheres subject to explosion hazards.
The manufacturer cannot be held liable for any damage result-
ing from use of the focusing optics contrary to the designated
use. Such use is at the sole risk of the user.
6.2 Technical measures
Condition of the laser The laser product may only be used if it is in perfect technical
product condition. Any faults, especially those affecting safety of the
unit, must be eliminated immediately!
Modifications Do not modify the laser product without previous consent of

TRUMPF as this may impair the safety of the laser product.
Spare parts Spare parts must comply with the requirements specified by
TRUMPF. This is guaranteed with original spare parts.
Software Do not modify the software programs in programmable compo-

nents.
Cables and hoses Always lay laser light cables and the electric cables and hoses
in such a way that they are protected or in sufficient height and
the minimum bending radius is observed.
Keep the cables and hoses away from:

■ traffic routes.
■ moving or heavily vibrating machine parts.
Separate ground cable If the ground cable cannot be connected via the mains cable,
the ground cable must be connected separately to the ground-
ing of the building. The ground cable must be installed protected
so that it cannot be damaged or disconnected. The ground
cable may only be connected by trained electricians.
Protective covers Always cover the focusing optics, laser beam path and process-
ing points with protective covers, as far as possible. Protective
1‐20 Measures of the user 2019-03 21-01-29-CRen

covers must be designed in such a way that laser light cannot
escape.
Protective covers can be:

■ Housings in which focusing optics and processing point are
located.
■ Walk-in protective cabins.
All parts of protective covers that can be opened by the operat-
ing personnel during operation must be monitored. Monitoring
must be designed such that laser light emission is stopped
immediately when a protective cover is opened.
Protective covers that are opened only for repair have to be
monitored in the same way. If they are not monitored, tools
must be required for opening them.
TRUMPF laser devices have safety circuits that guarantee the
described safety function when they are appropriately wired.
More information is given in the interface description of the laser
devices.
Walk-in protective cabins should additionally be equipped with
motion detectors or similar equipment. This allows to determine
whether there are persons in the protective cabin even if the
cabin door is closed.
Cordoning off the Cordon off the areas in which laser light can escape to prevent
hazardous area access of unauthorized persons, for example by using code
locks or suitable signaling devices.
6.3 Organizational measures
Laser safety officer If your company operates a class 3B, 3R or class 4 laser prod-
uct, appoint a laser safety officer. Make sure that this person is
qualified and can assess the hazards caused by the laser and
take appropriate measures. Put this laser safety officer in
charge of supervising the protective measures against hazards
caused by the laser.
Selecting and qualifying As the laser device user, only employ trained or instructed staff.
personnel Clearly specify the individual responsibilities of the persons for
operation, setup and servicing.
Registering the laser As the user, you are obliged to report the operation of class 3B
product and class 4 laser products to the authorities responsible for
laser safety.
If you have any questions, contact the local sales office of
TRUMPF.

The competent authorities in Germany are:
■ the professional association.
■ the industrial inspection board.
Skilled electrician According to the rules of electrical engineering, any work on the
electrical system of a laser product may only be carried out:
■ by an electrician.
■ by instructed persons under the supervision and guidance of
an electrician.
6.4 Observing standards and regulations
Some important standards and regulations which you have to

observe when operating a laser product are listed in the follow-
ing table. This list is for information purposes only and probably
incomplete.
As the operator, you are responsible for ensuring that the stand-
ards and safety regulations in force in your region are observed
as far as they are mandatory.
International standards EN 60825-1 Safety of laser products

IEC Radiation safety of laser products
60825-1
EN 207 Filter and safety glasses against laser radiation
(laser safety glasses)
EN 60204-1 Electrical equipment of machines
Tab. 1-2
German accident prevention BGV A 3 Accident prevention regulations

regulations "Electrical systems and equipment"
BGV B 2 Accident prevention regulations "Laser radiation"
BGV B 3 Accident prevention regulation "Noise"
TRGS 400 Determining and judging the risks involved by hazardous
substances: Requirements
TRGS 402 Determining and judging the concentrations of hazardous
substances in the air in working areas
TRGS 900 Limit values in air at working place - air limit values
Tab. 1-3
6.5 Behavior in certain operating stages
Standard operation Operate the laser product only when all protective and safety rel-
evant devices, - e.g. Emergency Stop equipment, protective cov-

ers, safety contacts, exhausters - are in place and fully opera-
tive.
Open the safety circuit of the light path in question when an
error occurs. Have any defects eliminated immediately.
Maintenance Service work may be carried out by trained personnel only.

For maintenance and repair, open the safety circuits of all
affected light paths and make sure that they remain open for the
entire duration of the work.
Before working on the electrical system of the laser product,
turn the main switch OFF. Lock the main switch in this position
using a shackle padlock.
Carry out the adjustment, maintenance and service work stated
in these operating instructions in due time. Observe information
regarding the replacement of parts.
Check the correct functioning of the safety devices of the laser
product regularly.
6.6 Behavior in case of emergency
Emergencies are understood here as meaning:

■ Laser light exits unexpectedly.
■ A part of the machine in which the laser product is operated
makes uncontrolled movements.
■ A fire or explosion can be triggered.
■ Substances which may affect health are leaking.
If it must be expected that these or similar events may injure
persons or damage material, appropriate measures must be
taken.
If an emergency was caused by the laser product, press an E-
Stop push-button to stop laser light emission and movements
of the machine.
Further measures depend on the situation.
As the user of the laser product, TRUMPF recommends you
identify the possible hazards in a risk analysis and define suita-
ble measures to diminish these or personal first-aid measures.
Prepare an operating instruction establishing what to do in an
emergency. Attach the operating instruction in the dangerous
area in a way that everyone can read.

6.7 Selecting and qualifying personnel
Only use trained and instructed staff.
Define the responsibilities on the laser product for:

■ Setup
■ Operation
■ Maintenance
Any work on the electrical equipment of a laser product must be
carried out by a trained electrician only.
Instructed personnel may work on the electrical equipment if

■ the rules for electrical safety are observed.
■ the work is carried out under the supervision and guidance
of a trained electrician.
6.8 Instructing the personnel
Operator’s obligations As the operating company, make sure that all persons operating
the laser product have the knowledge and qualifications to do
so. In particular, the personnel needs the required awareness of
possible dangers that might be caused by the laser product.
Reading the operating Before starting the work, the personnel entrusted with work on
instructions the laser product must have read the operator’s manual and the
chapter "Safety" in particular. This applies especially to persons
working only occasionally on the laser product, e.g. during main-
tenance.
Training with TRUMPF If required, TRUMPF offers trainings for operators and personnel
responsible for maintenance. Please contact the TRUMPF serv-
ice department.
Directives Inform any person in the dangerous areas by means of direc-

tives. Attach the directives clearly visible and protected in the
dangerous areas.
Directives are short informative texts, mostly not longer than a

page, which present all essential information to
■ avoid dangers as far as possible
■ act correctly if accidents occur in spite of safety measures.
Signs Please observe the labels attached to the laser product. Ensure
that the labels are in a legible state. Any labels that are dam-
aged or not longer legible must be replaced.

For further information on the labels: see section "Labels"
6.9 Wearing personal safety equipment
If your risk assessment for the laser product shows that techni-
cal measures are not sufficient, persons can be protected in
addition by wearing personal safety equipment.
Examples:
■ Laser safety glasses to protect the eyes against escaping
laser light.
■ Protective gloves to protect the hands against hot workpie-
ces.
■ Respiratory equipment to protect the respiratory tract against
hazardous substances.
Make sure that the provided personal safety equipment is effec-
tive. For laser safety glasses, for example, the filtering glasses
have to be suitable for the wavelengths of the laser light emitted
by the laser. The optical density of the filtering glasses must be
adapted to the beam intensity.
Check the provided personal safety equipment on a regular
basis. The safety equipment must be in perfect condition. Laser
safety glasses must be free of damage and scratches.
Stipulate wearing of personal safety equipment clearly, for exam-
ple in a directive.
Make sure that this regulation is observed.
Punish any violation of this regulation.

Chapter 2
Assembly and installation

Assembly and installation 2‐3
1 Integration into a system environment 2‐4

1.1 Fastening 2‐4
1.2 Clearances 2‐7
1.3 Example 2‐8
2 Installation 2‐12
2.1 Overview of the connections 2‐12
2.2 Principles, general rules 2‐13
2.3 Safe combination of laser device, laser light 2‐14
cable and focusing optics
Characteristics of safe combinations 2‐14
Dangers due to impermissible combina- 2‐15
tions
Information required to assess the safety 2‐16
of a combination
2.4 Connection of the laser light cable (LLK) 2‐18
Connecting the laser light cable to the 2‐21
focusing optics
21-01-29-CRen 2019-03 Assembly and installation 2‐1

2.5 Connections for cooling unit 2‐25
2.6 Connections for lens with exhauster 2‐29
Commissioning of a lens with exhauster 2‐29
2.7 Connections on the crossjet 2‐31
2.8 Connection for cutting optics 2‐36
2.9 Connection for proximity switch 2‐37
3 Ambient conditions 2‐39

3.1 Determining the necessary cooling water tem- 2‐40
perature
4 Using shielding gas 2‐41

4.1 Gases during laser welding 2‐41
4.2 What is shielding gas used for? 2‐41
4.3 Shielding gases 2‐42
Nitrogen (N2) 2‐43
Argon (Ar) 2‐43
Helium (He) 2‐43
Recommendations 2‐43
4.4 Shielding gas supply 2‐44
Single tube 2‐45
Multiple tube 2‐46
Conical nozzle 2‐48
Other methods 2‐50
4.5 Arrangement of the shielding gas nozzles 2‐50
Pulsed lasers 2‐51
cw lasers 2‐52
Welding at edges 2‐53
4.6 Dosing shielding gas 2‐53
4.7 Effect of the shielding gas 2‐56
2‐2 Assembly and installation 2019-03 21-01-29-CRen

Assembly and installation
Commissioning of the focusing optics:

■ is done by a service engineer of TRUMPF during the com-
missioning of a laser device, if the focusing optics is deliv-
ered together with a laser device.
■ is done by the user after start-up of an existing laser device,
if you purchased the focusing optics afterwards.
The following conditions must be fulfilled:

■ The necessary safety equipment must have been installed
and must be ready for operation.
■ Suitable laser safety glasses must be at hand.
■ If additional media are required, they must have been pro-
vided:
− Shielding gas
− Compressed air
− Exhauster
− Cutting gas
■ There must be enough samples for the commissioning proce-
dure. A suitable workpiece holder for the samples must be
provided.
21-01-29-CRen 2019-03 Assembly and installation 2‐3

1. Integration into a system environment
The focusing optics is composed by modules according to the

requirements of your application. This means that each focusing
optics has different specifications:
■ for the dimensions of the focusing optics
■ for the fastening of the focusing optics.
■ for the spaces which have to be kept free around the focus-
ing optics.
Documents Dimensional details about the focusing optics and the clearan-
ces that have to be maintained are described in the following
documents:
■ in the dimensional drawing of the focusing optics
■ in the installation instructions for the processing optics D70,
Doc. No.: 22-24-01-DH
These documents have been delivered together with your laser
device or with the separately delivered focusing optics.
Dimensional drawing and The dimensional drawing contains:

installation guideline ■ all dimensions in millimeters [mm]
■ Clearances to be maintained in millimeters (mm).
■ Letters as a reference to the installation guideline.
How to deal with dimensional drawings and installations instruc-
tions is described by means of an example in the following sec-
tions:
1.1 Fastening
Fastening of the focusing optics is determined by the modules

built in.
When a monitored protective glass cassette is used, the fasten-
ing must be designed so that it is electrically insulated.
There are the following fastening methods for the focusing

optics:
■ at the extension “short”.
■ At the extension “short” and additionally at the clamping
flange.
■ At the cube with its different versions:
− Empty cube.
− 0° cube.
− 90° cube.
■ At the 2 x 90° double deflection.
2‐4 Integration into a system environment 2019-03 21-01-29-CRen

Fastening elements To fasten a focusing optics with cube to a robot, a DIN-ISO con-
nection plate is available.
Fastening specifications The following picture informs you how to find information on the
fastening in the relevant dimensional drawing or in the installa-
tion instructions.
21-01-29-CRen 2019-03 Integration into a system environment 2‐5

Dimensional drawing of the focusing optics (example) Fig. 2-1

In addition to the dimensions, you will also find letters on the
drawing. The arrow points to the letter g.
"g" is a reference to the installation instructions, document no.:
22-24-01-DH, the dimensional drawing for the bores "0° cube".
mb000114
Dimensional drawing for "g" in the installation instructions Fig. 2-2
1.2 Clearances
Space has to be kept free around the focusing optics, especially

for:
■ for an unhindered emission of laser light.
■ for observing the working distance, even if different focal
lengths of lens are used.
■ for adjustment work:
− for aligning the focusing optics.
− for adjusting the focal position
− for adjusting the picture sharpness of eyepiece or cam-
era.
− for adjusting the cross hairs.
− adjusting the illumination of the camera picture
− for defocusing the focusing optics.
■ for maintenance and service work:
− for connecting and disconnecting the LLK.
− for connecting supply lines such as compressed-air, cut-
ting gas, exhauster, cooling unit.
− for removing and fitting the lens protection.
− for removing and fitting the lens.
− removing and fitting the cassette module

− for positioning tools.
− for attaching measuring devices.
Clearances are also required:

■ when constructing the carrier system, particularly if the focus-
ing optics is used as a mobile system.
■ when attaching a protective cover.
Specifications for Specifications for clearances which have to be observed are

clearances to be observed given in the following documents:
■ in the dimensional drawing of the focusing optics
■ in the installation instructions for the processing optics D70,
Doc. No.: 22-24-01-DH
The example in the next section gives information on the mean-
ing of the letters in the dimensional drawing and which specifica-
tions are to be found in the installation guideline.
1.3 Example
A dimensional drawing of a focusing optics is shown below as

an example of the code letters.

min. Bie ge ra dius R200
u
3
52 8
7
h
g k
54,5 ±3
74
6
4
88
15
5 15
9
Spülga s+MDE
10 Ga szuführung
c a . 60l/ min
11 c a . 0,9 ba r
162,5
58 w
262 ±0,2
ve rste llba r
10mm
Ausric htung
12 de r MDE-Düse
zur Stra hla c hse
be a c hte n
°
<16
60,5
52,6 59
37 39
97,5
Dimensional drawing of the focusing optics (example) Fig. 2-3

The installation instruction 22-24-01-DH for the focusing optics
D70 supplements the dimensional drawing with important notes
and dimensional details to be observed when installing the focus-
ing optics in machines and devices. The areas and single com-
ponents in the dimensional drawing which are marked with a let-
ter are described in detail in the installation directive.
Letters used Below you find a short summary of the letters used in dimen-
sional drawings and information on their meaning.
■ [a] Plug receptacle B.
Notes on the bending radius LLK-B, insert depth, fuse and
space requirements for the adjustment work.
■ [b] Collimation with defocusing.
Note on the space requirements for the adjustment work.
■ [c] Extension "short".
Information on the installation of the focusing optics with
hole pattern.
■ [d] Clamping flange.
hole pattern.
■ [e] Empty cube.
hole pattern.
■ [f] 90° cube.
hole pattern.
■ [g] 0° cube for observation.
hole pattern.
■ [h] Flange for sensor module/flange with protective filter/
flange with edge filter.
Notes on the space requirements for adjusting and fastening
the components of the focusing optics or the sensor module.
■ [i] Locking screw for sensor interface.
Notes on safety screws (hexagon socket with pin).
■ [k] Observation optics.
Note on the area marked in the dimensional drawing, which
has to be kept accessible for adjustment work.
■ [m] Lens, lens protection.
Note on the space requirements for the maintenance work.
■ [n]Cutting optics.
■ [p] Lighting module D70.
Note on the space requirements for the maintenance work
and optimum lighting of the workpiece.
■ [r]Pivot joint.
Information on flange surface and turning range.

■ [s] Dual focus optics with fixed point spacing.
Information on space required for adjustment work and cross-
reference to data sheet 22-24-26-BC.
■ [t] Dual focus optics with variable intensity.
Information on space required for adjustment work and cross-
reference to data sheet 22-24-32-BC.
■ [u] Connecting cables.
Note on the area marked in the dimensional drawing, which
has to be kept clear for the connecting cable.
■ [v]Crossjet.
■ [w] Cassette module.
■ [x] Plug receptacle D.
Notes on the bending radius LLK-D, insert depth, fuse and
space requirements for the adjustment work.
■ [y] 2 x 90° double deflection.
hole pattern.
Details are to be found in the installation directive 22-24-01-DH.

2. Installation
2.1 Overview of the connections
0030-31-T
4
1 Connection for laser light cable 4 Cooling water connections for

(LLK-B) lens cooling ring
2 Cooling water connections plug 5 Cooling water connections for
receptacle (LLK-B) collimation cooling ring
3 Flange for observation unit
Connections on a focusing optics D70 Fig. 2-4
The possible connections on a focusing optics D70 are descri-

bed in the following sections.
In case of attached additional modules there are also the follow-
ing connections available.
Module Additional connections

Lens with exhauster Connections for air supply and
exhaust air (see "Connections for
lens with exhauster", pg. 2‐29)
Crossjet Air supply connection
optional: shielding gas (see "Connec-
tions on the crossjet", pg. 2‐31)
optional: MDE nozzle (see "Connec-
tions on the crossjet", pg. 2‐31)
2‐12 Installation 2019-03 21-01-29-CRen

Module Additional connections
Cassette module Connection for proximity switch (see
"Connection for proximity switch",
pg. 2‐37)
Cutting optics Connection for cutting gas supply
(see "Connection for cutting optics",
pg. 2‐36)
Camera and illumination module Electrical connections (see operating
instructions for camera and operat-
ing instructions for illumination mod-
ule D70 when operated with camera)
Tab. 2-1
2.2 Principles, general rules
Laser light is a versatile tool of industrial material processing.
The technology of solid-state lasers combines two advantages:

■ Solid-state lasers can reach kilowatts in the double-digit
range, also as continuous wave.
■ The light of the solid-state lasers can be guided and formed
by means of glass optics (lenses, mirrors, prisms and fiber
glass).
But the advantages have their price: The higher the laser power
used, the higher are the demands on cleanliness.
Requirements All volumes penetrated by laser light must be free of absorbing

gases or suspended particles.
Otherwise, when the laser light penetrates the volumes, the pres-
sure inside them may increase rapidly and damage or destroy
parts of the optical components.
All surfaces of optical components penetrated by laser light or
reflecting laser light must be completely free of absorbing depos-
its or particles.
Otherwise, the deposits or particles may burn in the surface of
the optical components. This normally destroys the optical com-
ponents.
Even if the components are not destroyed, a soiled focusing
optics may heat excessively. This may shift the focal position.
As a result the process quality may be reduced.
Practice For the use of focusing optics and laser light cables (LLK) this
means:
As long as the focusing optics are not connected to LLK
plugs, plugs must be inserted into the plug receptacles to avoid
penetration of dirt.
21-01-29-CRen 2019-03 Installation 2‐13

As long as the optical plugs of the LLK are not connected to
the incoupling optics or focusing optics, protective caps must
be on the LLK plugs preventing the dirt from penetrating into the
protective glasses of the LLK plug.
The joints between the LLK plugs and the focusing optics must
be sealed by means of adhesive tape.
In highly contaminated environment, it is necessary to protect
the joints by means of protective sleeves to avoid the penetra-
tion of dirt.
The plug receptacles must be in horizontal position when
connecting or disconnecting the optical plug from the focusing
optics. This prevents the particles from entering the plug recepta-
cles from above.
Make sure that the plug receptacles and the LLK plugs are
unprotected only during connection and disconnection. Never
touch the surfaces of the optical components with your fingers.
2.3 Safe combination of laser device,

laser light cable and focusing optics
Characteristics of safe combinations
A combination of laser device, laser light cable and focusing

optics is safe when the following criteria are fulfilled:
Wavelength Laser device, laser light cable and focusing optics must be
designed for the same wavelength spectrum.
Rated output Laser light cable and focusing optics must be suitable for the
rated power of the laser device.
Numerical aperture The numerical aperture of the laser light cable and the focusing
optics must not be smaller than that of the laser device.
Laser device Optical laser cable Focusing optics

Wavelength = LLK, =focusing optics =laser device, =focusing optics =laser device, = LLK
Rated output ≤ LLK, ≤focusing optics ≥ Laser device ≥ Laser device
Numerical ≤ Laser light cable ≥ Laser device, ≤ focusing optics ≥ Laser light cable
aperture
Tab. 2-2

Dangers due to impermissible
combinations
Laser radiation escaping

DANGER
Laser radiation can damage skin and eyes. Damage to
eyesight or even complete blindness can result.
Ø Only use safe combinations of laser device, laser light cable
and focusing optics.
Housing of focusing optics gets hot

DANGER
Touching the focusing optics can lead to serious burns.
Ø Only use safe combinations of laser device, laser light cable
and focusing optics.
Numerical apertures cannot be combined
Numerical aperture of the If the numerical aperture of the focusing optics is smaller than
focusing optics is too small the numerical aperture on the decoupling connector, a part of
the laser light hits the aperture of the focusing optics. The hous-
ing of the focusing optics can heat up strongly as a result
(> 300 °C). The following dangers result from this:
■ Fire hazard: Materials in the environment of the focusing
optics can catch fire.
■ Risk of burns: People who work with the focusing optics
may suffer burns.
■ Risks from escape of laser radiation: People in the envi-
ronment of the focusing optics may be injured by escaping
laser radiation. Skin burns and loss of eyesight are possible.
Numerical aperture of the If the numerical aperture of the incoupling connector of the laser
laser light cable is too small light cable is smaller than the numerical aperture of the laser
device, a part of the laser light is coupled into the connector of
the laser light cable. This results in increased scattered light.
The laser devices switches off automatically.
Wavelength spectrums do not match
Focusing optics is not Focusing optics are designed for defined wavelength spectrums.
designed for laser device If a focusing optics is operated with a different wavelength than
specified, unforeseen reflections and transmissions to optical
components may occur. The housing of the focusing optics can

heat up strongly as a result (> 300 °C). The following dangers
result from this:
may suffer burns.
■ Risks of laser radiation in eyepiece and stereo micro-
scope: People who look into the eyepiece or the stereomi-
croscope during the processing operation can lose their eye-
sight.
Focusing optics is not designed for the rated power of the

laser device
Rated power of the laser A focusing optics will be damaged if it is operated with a higher
device is too high power than that which is specified. The housing of the focusing
optics can heat up strongly (> 300 °C). The following dangers
result from this:
may suffer burns.
Laser light cable or focusing optics are not from TRUMPF
Unknown risks When the laser device is combined with components that are
not from TRUMPF, the integrator or the operator must draw up
a risk assessment for the combined machine. This risk assess-
ment must include risks that could occur through the combina-
tion of the individual components.
Information required to assess the safety

of a combination
Information on the laser Information on the numerical aperture and on the wavelength
device spectrum is available either in the user's compartment or on the
incoupling optics.

Information in the user's compartment (example TruDisk Fig. 2-5
FD17)
Information on the incoupling optics (example TruDisk FD27) Fig. 2-6
Information on the laser Information on the permissible wavelength spectrum and the per-
light cable (examples) missible numerical aperture are to be indicated on the incou-
pling connector and on the outcoupling connector. The name-
plate contains additional information about the laser light cable.
1 Designation 5 Green border = LLK for green

2 Document number/Index laser light
3 Serial number 6 Numerical aperture
4 Material number 7 Permissible spectrum of wave-
lengths
Information on laser light cables (examples) Fig. 2-7
Information on LLK-D NA01 (green) Fig. 2-8

Information on LLK-D 100/400 µm NA01 double-core Fig. 2-9
Depending on the light laser cable, the information on the incou-

pling connector can deviate from that on the outcoupling connec-
tor.
1 Information on the incoupling 2 Information on the outcoupling

connector connector
Information on LLK-D NA0067/015-01 HP Fig. 2-10
Information on the focusing The processing optics contains information on power, numerical
optics aperture and wavelength spectrum on the plug receptacle.
Information on processing optics (example) Fig. 2-11
2.4 Connection of the laser light cable

(LLK)
Laser light cable An LLK-B or LLK-D laser light cable is used.

LLK-B
1 2
0030-09-T
3
1 Plug receptacle B 3 Locking screw

2 Optical plug of the laser light
cable
Connection of LLK-B to focusing optics Fig. 2-12
The LLK-B is available in the standard lengths 4 m, 6 m, 8 m,

10 m, 15 m and 20 m.An extension in steps of 10 m is possible.
The optical plug of the laser light cable LLK-B is inserted into
the plug receptacle B and fixed with the locking screw.
LLK-D 2
1 3
5 4
ct-00274
1 Plug receptacle 4 Push-button
2 Dust cover 5 Retaining ring
cable
Connection of LLK-D to focusing optics Fig. 2-13
The LLK-D is available with the standard lengths 10 m, 15 m,

20 m, 30 m, 40 m, 50 m, 60 m, 80 m and 100 m. Further
lengths are available on request.
The optical plug of the laser light cable LLK-D is inserted into
the plug receptacle D and fixed with the locking screw.

LLK protection 1 2
ct-00275
1 Plug receptacle LLK-D 3 Adhesive tape, 19 mm
cable LLK-D
Fig. 2-14
Note
To protect the LLK from dirt, TRUMPF recommends sealing the
disconnection point between the LLK plug and the plug recepta-
cle of the focusing optics with adhesive tape.
In a contaminated environment (e. g. dust, oil vapor), TRUMPF
recommends the additional use of a protective sleeve.
Parts Designation Material No. 1432345

Adhesive tape PVC, 19 mm 1420313
Protective sleeve 1416727
Tab. 2-3
Note
For sealing the disconnection point, use exclusively the adhe-
sive tape specified here.
Fiber core diameter Depending on the laser device used, the laser light cables are
available with various fiber core diameters:
■ 50 µm.
■ 75 µm.
■ 100 µm.
■ 150 µm.
■ 200 µm.
■ 300 µm.
■ 400 µm.
■ 600 µm.
Note
Contact the service department of TRUMPF if the LLK is dam-
aged. Change a damaged LLK only if the service department of
TRUMPF explicitly agreed to it.

Further information can be found in the operating instructions of
your laser device.
Safety A contact ring inside the plug receptacle and contact pins on
the optical plug guarantee that the laser device will only guide
laser light through the laser light cable when the optical plug is
correctly plugged in the plug receptacle of the focusing optics.
Installing the laser light Ensure that the laser light cables are installed without tensile
cables stress, buckles and torsion-free.
bend radius The bend radius of the laser light cable must not be smaller
than 200 mm.
Connecting the laser light cable to the

focusing optics
The following instructions describe how to proceed step-by-step

when connecting an LLK to a focusing optics.
In the following instructions, we assume that the optics cannot

be rotated on the carrier. If the optics can be rotated, you can
vary the described procedure as mentioned above:
■ Mount the focusing optics.
■ Rotate the focusing optics into a horizontal position.
■ Connect the LLk as described below.
Conditions
■ This concludes the complete assembly of the focusing optics.
■ You have removed the transport packaging of the focusing
optics and put it on a clean surface.
■ The plug receptacle of the focusing optics is closed with a
sealing plug.
■ The LLK plug you want to connect to the focusing optics is
flexible so that it can be plugged in the plug receptacle with-
out applying tensile force to the LLK.
■ A protective cap is attached to the LLK plug.
■ The carrier on which you want to mount the focusing optics
is mechanically and electrically, if required, prepared for
mounting.
Means, Tools, Materials

■ Adhesive PVC tape, 19 mm, material no.: 1420313
■ LLK-D protective collar, material number 1416727

Dirt in beam guideway!
NOTICE
This may destroy the LLK or focusing optics.
Ø Leave openings on LLK and focusing optics unprotected as
short as possible.
Ø Put the shaft of the plug receptacle in horizontal position as
long as the plug receptacle of the focusing optics is open.
Ø Do not touch optical surfaces.
Plug receptacle and LLK (sealed with adhesive tape) Fig. 2-15
1. Store the focusing optics such that the shaft of the plug
receptacle for the LLK is in a horizontal position.
Remove the sealing plug from the plug receptacle Fig. 2-16
2. Remove the adhesive tape from the plug receptacle of the
focusing optics.
3. Remove the adhesive tape from the LLK plug (1).
4. Press the locking pin down (2).
5. Push the sleeve towards the focusing optics (3).
6. Remove the plug (4).

Remove the protective cap from the LLK plug Fig. 2-17
7. Remove the adhesive tape from the LLK plug (1).
8. Remove the protective cap from the LLK plug. by turning
protective cap to the left (bayonet locking) (2) and (3).
Steps for mounting Fig. 2-18

9. Immediately plug in the plug of the LLK in the plug recepta-
cle of the focusing optics (1) ... (3).
10. Immediately put an adhesive tape around the joint and
press it on tightly (4).
Mounted and taped plug receptacle and LLK Fig. 2-19

11. Join sealing plug and protective cap and store them carefully.
Both parts will be needed when you separate the focusing
optics and the LLK again.
12. Mount the focusing optics to the support.

13. If any, establish all other connections to the focusing optics
(electrical plugs, cooling water hoses).
14. Lay LLK and other connected lines such that they have suffi-
cient room for movement.
0260-47-T
1 Adhesive type 3 Focusing optics
2 Sealing plug and protective
cap
Mounted protective sleeve Fig. 2-20
15. If there is considerable pollution in the environment, for
example due to dusts or oil, put the protective sleeve
around the plug receptacle and the LLK plug and close it.
You may now use the focusing optics.

2.5 Connections for cooling unit
ct-00276
1 Supply connection 2 Connection, return
Fig. 2-21
One pair of hoses, supply and return (hose set black/blue), sup-
ply the focusing optics with cooling water. When using an LLK-
D, the optical plug is also cooled with water.
Connections on the plug Heat arising at the transition point of laser light cable and colli-
receptacle mation unit is dissipated through the connections on the plug
receptacle.
Additional cooling Various cooling units can be used for additional cooling of the
focusing optics components:
■ Cooling sleeve for plug receptacle D.
− required starting from 8 kW of mean laser power.
■ Cooling ring for collimation.
− required for dual focus optics with integrated collimation
from 600 W of average laser power.

■ Cooling ring for lens.
− required for welding lens from 600 W of average laser
power.
■ Cooling unit for lens with connections on the cassette mod-
ule.
− required for welding lens from 600 W of average laser
power.
■ Cooling plate on cube.
− for empty cube 0° cube, 90° cube and 2 x 90° double
deflection.
■ Crossjet cooling plate 280-600.
− for lens focal length f = 280 mm to f = 600 mm.
The cooling water flows through the parts in the following order:
plug receptacle - cooling sleeve of plug receptacle D (if LLK-D
is used) – collimation cooling ring – lens/cassette module cool-
ing ring - cube cooling plate - crossjet cooling plate 280-600 -
plug LLK-D (if LLK-D is used).
The supply always reaches the plug receptacle first.
The following figure shows how the hoses are assembled when
using the collimation and lens cooling rings and when using the
collimation and cassette module cooling rings.

1 1
6 6
2
2
3
3
4 4
7
5
0031-02-T
8
1 Supply 5 Cooling ring for lens

2 Umbilical 6 Return
3 Cooling ring for collimation 7 Lens
4 Umbilical 8 Cassette module
Hose installation if cooling rings and a cassette module are Fig. 2-22
used (examples)
Cassette module The connections for the cooling water can be attached to three
connections sides of the focusing optics. Close unnecessary connection
holes with plugs.
Cooling water hoses The connections at the focusing optics are automatically acting
couplings. The length of the cooling water hoses is adapted to
the selected laser light cable. The following cooling water hose
is used:
■ Outside diameter 8 mm.
■ Inside diameter 6 mm (hose set black/blue).
Note
The focusing optics is cooled by the laser device cooling unit
sufficiently only if the cooling water hoses are shorter than
50 m. If the laser light cable is longer than 50 m, an additional
cooling unit must be used for the direct cooling of the optics.
The quality of the cooling water of the cooling unit must be the
same as the quality of the cooling water in the laser device.

Cooling water Normally the cooling water of the laser device is also used to
cool the focusing optics.
Cooling water contains DI water enriched with anticor-

CAUTION rosives!
Ø Wear safety glasses and disposable gloves.
Ø Protect clothing from contact with cooling water.
Ø Keep cooling water away from eyes and mouth.
Ø Flush eyes and mouth immediately with drinking water to
remove any cooling water.
Ø Wash hand and parts of the skin that have come into con-
tact with cooling water.
Cooling water for external In case of external cooling, the cooling water must have the fol-
cooling lowing quality:
■ The cooling water has to comply with the VDI Directive 3803
(Appendix A: Recommended values for the water quality in
RLT systems).
The pH value of the cooling water must always be < 8.5
because it flows through aluminum components inside the
focusing optics.
■ Particle size < 200 µm.
Note
The focusing optics that has been operated in a cooling circuit
with the water quality described above, must be rinsed thor-
oughly before it is operated in the cooling circuit of the laser
device to avoid contamination of the laser device. The external
cooling circuit must remain completely separate from the cooling
circuit of the laser device.
Supply Temperature 18 °C to 25 °C
Pressure max. 6 bar
Flow ≥ 60 l/h
Tab. 2-4
Note
If corrosion protection is stipulated for the external cooling
device, it is essential that it is used. In case of non-compliance,
corrosion residues may cause contamination of the focusing
optics and may reduce the flow rate of the cooling water.
TRUMPF recommends the anticorrosive KI 640 HD. There are
no long-term experiences for other anticorrosives.

2.6 Connections for lens with exhauster
0030-32-T
3 1
2
1 Exhaust air connection 3 Supply air connection

2 Lens with exhauster 4 Adapter for exhauster
Connections on the lens with exhauster Fig. 2-23
Supply air The supply air is guided through a connection kit into the lens
protection. The supply air deflects material particles and material
vapors which are scattered in the direction of the protective
glass.
Compressed air 1 bar ± 0.3 bar

Air consumption approx. 55 l/min
Tab. 2-5
Exhaust air The exhaust air together with the supply air forms a closed vol-
ume flow. The metal particles and metal vapors are extracted
and filtered through the exhaust funnel. With a correct adjust-
ment, the volume flow of air supply and exhaust air does not
reach the molten mass, thus also permitting the use of shielding
gas.
Vacuum pressure 14 mbar ± 2 mbar

Volume flow 50 to 70 m3/h
Power consumption of the exhauster 1.5 kW
Arising amount of dust up to 0.1 l/h
Tab. 2-6
Commissioning of a lens with exhauster
1. Check protective glass and clean it, if necessary (see chap-

ter "Maintenance").

1.5
1.6
1.7 1.3
1.1
1.2
2.3 2.6
2,7
2.1 2.2
2.4
2.5
0030-53-S
2.0
1.1 Exhauster 1.6 Power supply connection 2.3 Hose ∅ 6

1.2 Filter equipment 1.7 Signal line connection 2.4 Connection, straight
1.3 Measuring tube set 2.0 Connecting kit 2.5 90° connection
1.4 Actuator for exhaust air pres- 2.1 Fast-action coupling 2.6 Display supply air pressure
sure 2.2 Hose ∅ 8 2.7 Maintenance unit supply air
1.5 Exhaust air vacuum display pressure
Exhaust system, scheme Fig. 2-24
2. Connect supply air to the connecting kit components. Adapt
the length of the umbilicals to the local conditions.
Note
Observe the functional order of the elements (see "Fig.
2-24", pg. 2‐30). The order must not be changed.
3. Install the meter tube set in the outlet hose in a distance
between 1 and 5 m from the lens.
4. Check in the control program the following order:
− Exhaust air ON
− Supply air ON.
− Laser ON
Note
Keep the exhauster permanently on for cycle times smaller
than 2 minutes, as otherwise the protective motor switch will
react.

5. Adjust the supply air pressure to 1 bar while the valve on
the maintenance unit (2.7) is open. Read the value from the
supply air pressure indicator (2.6).
6. Adjust the exhaust air vacuum pressure to 14 mbar at the
exhaust air pressure actuator (1.4) by adjusting the speed.
Read the value from the exhaust air vacuum pressure indica-
tor (1.5).
You can optimize the value by changing the adjustment step by
step (e.g. 0.1 bar for the air supply or 1 mbar for the outlet bar)
in defined time intervals.
2.7 Connections on the crossjet
5
1
0031-03-T
4 3 2
1 Adapter with protective glass 4 Supply air connection

2 Crossjet CJ 5 Shielding gas connection
3 Shielding gas supply
Connections on the crossjet CJ Fig. 2-25

10 1 10 1 10 1
2 2
2
3 3
3
4 4
7 7 9 7 4
6
6 6
ct-00263
5 5
8
1 Lens 5 Coaxial MDE nozzle 8 Shielding gas supply

2 Cassette module 6 Crossjet TL 9 Shielding gas connection
3 Purge gas ring 7 Supply air connection 10 Connection for purging gas and
4 Adapter TL MDE nozzle
Connections on optimized crossjet TL, crossjet TL and the shielding gas supply Fig. 2-26
Note
TRUMPF recommends using a crossjet TL 20 (slot width
20 mm) for focal lengths of lenses up to 200 mm. A crossjet
TL 30 (slot width 30 mm) is typically used for focal lengths of
lenses greater than 200 mm to 300 mm, and a crossjet TL 40
(slot width 40 mm) is used for focal lengths of lenses starting
from 400 mm.
Air supply The air supply used is cleaned and dried compressed air.
Crossjet CJ Crossjet Crossjet Crossjet

TL 20 TL 30 TL 40
Slot width 20 mm 30 mm 40 mm
Pressure ≥ 5.0 bar 2.0 to 2.0 to 2.0 to
4.5 bar (rec- 4.5 bar (rec- 4.5 bar (rec-
ommended ommended ommended
3.5 bar) 3.5 bar) 3.5 bar)
Air con- approx. approx. 150 approx. 225 approx. 300
sumption 600 l/min – 300 l/min – 450 l/min – 600 l/min
Noise level > 90 dB(A) approx. 80 approx. 80 approx. 80
dB(A) dB(A) dB(A)
Compressed air Tab. 2-7
The compressed air used must comply with the specification

according to DIN ISO 8573-1:
■ Max. particle size 1 µm
■ Max. pressure dew point 7 °C
■ Max. oil concentration 1 mg/m3

The required pressure depends on the formation of splatter from
the respective welding application. In some cases, the value
may exceed the indicated upper limit.
Note
Note that the indicated pressure must be available at the com-
pressed air connection. The connected hose causes a pressure
loss, depending on the length and diameter of the hose.
TRUMPF therefore recommends designing long supply air lines
with an inside diameter ≥ 8 mm. For most standard crossjets,
there is a hose connection for an outside hose diameter of
12 mm.
Shielding gas Shielding gas is usually used for welding stainless steels, tita-
nium alloys and aluminum. Other materials are generally welded
without shielding gas.
Shielding gas is used to protect against the influence of air (O2,
N2) and to prevent corrosion. The use of shielding gas optimizes
the welding process and improves the welding result.
For operation with shielding gas, an inert gas supply must be
mounted (see "Shielding gas supply", pg. 2‐44).
Shielding gas is guided to the processing point via the shielding
gas connection when required.
Shielding gas Application-related (see "Using

shielding gas", pg. 2‐41)
Consumption approx. 15 – 25 l/min
Tab. 2-8
Note
To optimize the effect of the shielding gas, the shielding gas
must remain switched on for about 3 seconds before starting
and after finishing welding.
After being switched on, the shielding gas takes some time to
reach the workpiece.
After finishing welding, the melt must be briefly covered with
shielding gas during cooling.
Scavenging gas The purging gas connection with microfilter is delivered together
with the optimized crossjet TL. It supports the function of the
crossjet TL in the following manner:
The purging gas is passed into the cassette compartment and
the area below the protective glass via the purge gas ring. From
there, the purging gas flows downward, thereby preventing parti-
cles from entering. This reduces the contamination of the protec-
tive glass in addition to the effect of the crossjet TL. A second
purging gas path leads into the space between the focusing

lens and protective glass cassette. This strand additionally pro-
tects this sensitive space from the penetration of smoke residue.
Notes
■ The purging gas should also remain switched on during the
processing pauses, in order to keep the still-rising smoke
residue away from the protective glass.
■ The purging gas requirements meet the specification for the
supply air and crossjet. Shielding gas, e.g. nitrogen, can
also be used as the purging gas.
2
1
ct-00280
1 Purge gas ring 3 Filters

2 Protective glass 4 Cassette compartment
Path of purging gas in the cassette module Fig. 2-27
Note
Observe the following when changing the cassette in a strongly
contaminated environment:
Due to the purging gas, dirt particles can be stirred up and get
into the cassette compartment. Therefore, switch off the purging
gas supply before changing the cassette in this case.

The coaxial MDE nozzle is also attached to the purging gas con-
nection with microfilter.
MDE nozzle The MDE nozzle is attached to the crossjet (MDE means metal
vapor effect).
During the laser welding process, the laser light may be
reduced or deviated due to the particles in the metal vapor
(plasma torch). This may lead to welding depth fluctuations and
to irregular weld surfaces. To minimize this effect, TRUMPF has
developed a special coaxial metal vapor nozzle.
Cleaned and dried compressed air is supplied toward the proc-
essing plane via the connection for the MDE nozzle. The air
flow of the MDE nozzle eliminates the plasma torch.
ct-00299
1
Plasma torch with and without use of coaxial MDE nozzle Fig. 2-28
Pressure approx. 0.9 bar

Hose diameter 6 mm
Compressed air for purging gas and MDE nozzle Tab. 2-9

ct-00285
1 Purging gas connection 4 Lateral MDE nozzle
2 Connection for purging gas 5 Connection for lateral MDE
and MDE nozzle nozzle
3 Coaxial MDE nozzle
Connections to lateral MDE nozzle and coaxial MDE nozzle Fig. 2-29
The actually required pressure depends on the plasma torch of

the respective welding application
Note
Adjust the air consumption (flow rate) directly in front of the
MDE nozzle in the air supply hose by means of a suspended
solid particle flow meter and a reducing valve.
2.8 Connection for cutting optics
1
2
0030-34-T
1 Connection for cutting gas sup- 2 Cutting optics

ply
Connection to the cutting optics Fig. 2-30

Cutting gas Cutting gas is guided into the cutting nozzle via the cutting gas
connection.
The cutting gas type used depends on the application. A differ-

entiation between two applications has to be made:
■ Flame cutting using oxygen for mild steel
Cutting gas pressure 0.5 to 5 bar
■ Fusion cutting using nitrogen for stainless steel
Cutting gas pressure 3 to 25 bar
2.9 Connection for proximity switch
1 Connector proximity switch, 3 3 Cassette module

poles, M8 x 1 4 Sensor proximity switch
2 Protective glass cassette
Connection proximity switch protective glass cassette Fig. 2-31
The proximity switch signals whether a cassette is available or

not.
The proximity switch can be connected to a PLC or a monitor-
ing device by means of a 3-pole connector (M8 x 1).
BN +
BK A
0031-09-T
BU -
Pin assignment proximity switch Fig. 2-32
Operating voltage: 24 V DC.

Signal level on the output A:

24 V Protective glass cassette available
0 V Protective glass cassette not available
Tab. 2-10

3. Ambient conditions
Temperature Operation: +15 °C – +40 °C

Storage: +5 °C – +40 °C
Relative humidity at 40 °C: 40 %
at 20 °C: 90 %
Protection type: IP 54
Maximum acceleration: 3 g with 5 – 100 Hz
Tab. 2-11
The focusing optics must not be operated in an explosion

endangered environment.
Cooling water temperature If hot and humid air contacts the cold surfaces, condensate is
formed at certain temperatures.
To avoid the formation of water of condensation on the focusing
optics, the cooling water temperature must not be set to too
cold a value.
The required cooling water temperature is determined by meas-
uring the ambient temperature and humidity in the surroundings
of the focusing optics (see "Determining the necessary cooling
water temperature", pg. 2‐40). These measured values can be
used to read the temperature in the dew point diagram starting
from which the surrounding air will condense.
Note
The cooling water temperature must be at least 2 °C above the
indicated dew point temperature.
21-01-29-CRen 2019-03 Ambient conditions 2‐39

3.1 Determining the necessary cooling
water temperature
dew point temperature in °C
SG-02007
ambient temperature in °C
Dew point diagram Fig. 2-33
1. Measure ambient temperature (in the example: 36 °C).

2. Measure the relative humidity (80 % in the example).
3. Draw a vertical line in the diagram from the measured ambi-
ent temperature upwards until it intersects with the straight
line representing the measured humidity.
4. Draw a horizontal line from the point of intersection to the
dew point temperature.
5. View the dew point temperature (32 °C in the example).
The temperature of the cooling water flowing through the focus-
ing optics must be at least 2° C above the dew point tempera-
ture: In the example, the cooling water temperature should be at
least 34 °C.
Note
When determining the required cooling water temperature, also
observe the laser device requirements. In tropical countries, the
cooling of the focusing optics must be ensured using an exter-
nal cooling unit. TRUMPF also offers solutions for an external
chiller.
2‐40 Ambient conditions 2019-03 21-01-29-CRen

4. Using shielding gas
4.1 Gases during laser welding
During laser welding, gases are used in order to improve the

results and avoid deposits on the laser tools.
According to the type of use, a distinction is made between

■ Working gas
■ Shielding gas
■ Crossjet gas
Working gases are only necessary for welding with YAG-lasers
at large focal lengths. They suppress the absorption of laser
light in the plasma of the metal vapor.
The shielding gas displaces the air at the weld point and thus
prevents a reaction with the components of the air.
Crossjet gases are used for welding applications with a strong
production of splashes and vapor. The crossjet TL carries a
crossjet gas over the optics protecting it against splashes and
smoke deposit during the welding process.
The crossjet TL does not influence the melt and the shielding
gas.
The following section describes the use of shielding gas more in
detail. The use of working gases and crossjet gases are men-
tioned where the same conditions apply for several application
forms or where interactions arise, e.g. between shielding gas
and crossjet gas.
4.2 What is shielding gas used for?
Principle of laser welding The laser generates the laser light and thus the energy neces-
sary for the welding process. This energy is led to the joint of
the workpieces via the deflection mirror, laser light cable and
focusing device.
The workpieces themselves are arranged and fixed in such a
way that the focused laser beam can be guided exactly to the
joint. The focusing optics moves over the workpiece along the
joints. The high power density of the laser beam in the focal
point causes the material to melt and, to a small extent, to
vaporize.
The pressure of the escaping metal vapor can increase to such
a level that a vapor channel in the material is generated – the
so-called "keyhole". This keyhole penetrates the material a few
millimeters deep.
21-01-29-CRen 2019-03 Using shielding gas 2‐41

When the focusing optics moves over the workpiece the keyhole
also moves under the focusing optics. Behind it the melts flow
together. The molten and mixed material cools down and the
molten mass solidifies to a narrow welding seam.
Many molten metals react with the components of air. This
reduces the welding quality. The shielding gas displaces the
components of air and has a positive effect on the quality of the
welding seam.
4.3 Shielding gases
For laser welding metals, mainly inert (inactive) gases are used.
Inert gases do not react with the base material or only to a very
limited extent.
Recommended shielding gases are:

■ Nitrogen (N2)
■ Argon (Ar)
■ Helium (He)
Purity of the gas Industrially produced gases always contain a small amount of
impurities. The purity of the gases is indicated by a system of
digits.
1st digit = number of nines of the percentage
2nd digit = last digit of the percentage
Example: He 4.6 = Helium with purity 99.996 % (by volume)
Service life of a gas cylinder The service life of a gas cylinder can be easily calculated. Weld-
ing gases are supplied in gas cylinders. A gas cylinder contains
in most cases 50 liters of a gas which is under a pressure of
200 bar.
V . p
T=
SG-02006
Fig. 2-34
with T: Service life

V: Volume of the gas cylinder
p: Filling pressure
Q: Specific gas consumption
Tab. 2-12
2‐42 Using shielding gas 2019-03 21-01-29-CRen

Example:
V = 50 l, p = 200 bar, Q = 40 l/h
→ T = 50 l • 200 bar / 40 l/h = 250 h
Nitrogen (N2)
Nitrogen is a colorless, odorless and inert gas.

Nitrogen is suitable for welding chrome-nickel steel.
It is not suitable for use with zircaloy and titan materials
because it can combine with these materials despite its inert-
ness.
When melding steel with nitrogen it shall be considered that the
nitrogen lowers the stainless protection by taking out the chrome-
nickel fractions out of the steel.
Argon (Ar)
Argon is a colorless, odorless and inert noble gas contained in

air in a concentration of 0.93 % by volume. Argon is non-flam-
mable and non-poisonous. It is suitable as shielding gas for
chrome-nickel steel, zircaloy and titanium.
Helium (He)
Helium is a colorless, odorless and inert gas. Because of its

reduced density it is very light and quickly escapes upwards
when flowing out. For this reason, the consumption of helium as
shielding gas is considerably higher than for other gases.
It can be used as shielding gas for aluminum and Al alloys and
as addition when welding with nitrogen.
Recommendations
The following table (see "Tab. 2-13", pg. 2‐44) shows an over-
view of the recommended shielding gases.

Ar He N2 Remarks
Aluminum and alumi- - + - Smooth and polished weld seams are produced with helium or a
num alloys helium mix.
The use of argon causes blowholes in the material.
Hydrogen gases cause blowholes in the material.
High-quality weld seams can be produced with carbon dioxide
(CO2) or a helium-carbon dioxide mix. However, the weld seams
are less smooth and polished.
Chrome-nickel steel + - + On devices where gas can escape easily, the use of argon is rec-
ommended since it is heavier than nitrogen.
If corrosion is to be avoided under all circumstances, argon must
be used since nitrogen extracts chrome and nickel from the mate-
rial.
Titanium and tita- + - - Titanium reacts strongly with the components of air. As long as
nium alloys the weld cooling down still has a temperature of 200 °C, it is nec-
essary to cover the melting bath completely with argon (e. g. use
of a glove box).
Zircaloy + - - -
Copper - - - Copper must generally be welded without shielding gas. Shielding
gas substantially reduces the incoupling of laser light.
Shielding gas recommended for the material: + = yes, - = no Tab. 2-13
Note
The welding in narrow devices can result in self protection
because the metal vapor displaces the oxygen in the surround-
ings. In such cases, no shielding gas has to be used.
4.4 Shielding gas supply
Shielding gas can be guided to the processing point:

■ via a nozzle
■ via a clamping device of the workstation
The following parameters must be adjusted optimally for use:

■ gas, pure or mix
■ contact angle
■ contact area
■ gas flow
■ nozzle geometry.
The shielding gas supply must be adapted to the laser device
type (cw or pulsed), welding speed and welding seam.
TRUMPF offers some nozzles as standard supply, which are
described below in more detail.

Note
For use with the magnetic coupling, TRUMPF provides shielding
gas supplies in a stronger version. Further information can be
obtained from TRUMPF upon request.
Single tube
The single tube can be used as a controlled shielding gas sup-

ply applied over a small surface for spot welding with pulse
laser devices and all seam forms.
The single tube can be attached to the focusing optics with a
flexible mounting arm.
Recommendation:
■ Distance from the pipe end to the workpiece: 5 mm –
10 mm.
■ Angle between the pipe end and the workpiece: 30°.
Single tube Fig. 2-35
Round parts (∅ max. 300 mm) that cannot be rotated during

welding are covered evenly with shielding gas by single tubes
which are distributed around the circumference of the weld.

Multiple tube
In the case of multiple pipe, several pipes are connected with

one another by means of a distributor.
Prerequisites:
■ cw laser device.
■ Focal length of lens f = 200 mm.
ct-00277
1 Multiple tube with lateral MDE 3 Multiple tube, left 5 Jumper
nozzle 4 Multiple tube, right 6 Linear nozzle
2 Multiple pipe, rotatable
Fig. 2-36
Welding application Multiple tubes can be used for welding linear joints:
■ Butt joint.
■ Fillet seam.
■ Girth weld ∅ < 50 mm (larger ∅ can be considered linear
welds).
To cover a weld with shielding gas over a longer length (e.g. for
titanium and zircaloy), several multiple tubes can be coupled.
A distance of 5-10 mm to the workpiece starting with the lon-
gest pipe in the multiple pipe is recommended.

4
3
2 6
5
8
1
7
0061-51-T
1 Locking screw holder (2°x) 5 Holding plate
2 Clamping jacket 6 Fastening screws extension
3 Fastening screw clamping “short” (2°x)
jacket (2°x) 7 Locking screw distance (2°x)
4 Fastening screw cube (2°x) 8 Locking screw height (2°x)
Fastening and setting options Fig. 2-37
Multiple tube, rotatable The rotating multiple tube can be mounted with the clamping
jacket (2) on the crossjet support TL (f = 200) or on the crossjet
support CJ (f = 200) in any position.
The distance between focusing optics and the workpiece can be
adjusted as required (1).
Note
The effect of the crossjet TL may be impaired by the multiple
pipe.
Multiple tubes, left and right The multiple tubes left and right may be mounted with the hold-
ing plate (5) laterally on the cube (4) or on the extension
“short” (6).
The distance between the focusing optics and the workpiece
can be adjusted as required (7 and 8).
Multiple tube with lateral The lateral MDE nozzle is attached to the front tube of the multi-
MDE nozzle ple tube. In addition to allowing shielding gas to be used, it also
makes it possible to reduce the metal damping effect; see also
MDE nozzle.
Linear nozzle The linear nozzle is a further development of the multiple tube,
where the individual tubes are consolidated. Compared to the
multiple tube, the linear nozzle has the following advantages:

■ Better welding seam quality.
■ Smaller interference contour thanks to compact structure.
■ Can also be used if there is a greater distance between the
nozzle and workpiece.
Shielding gas hose The following shielding gas hose must be connected to the fast-
action coupling on the jumper:
Outside diameter: 8 mm
Internal diameter: 6 mm
Tab. 2-14
Depending on the welding application, reactors may be mounted

in different hoses to generate jets of gas of different intensities
in different pipes.
Conical nozzle
The conical nozzle contains a perlator. The perlator ensures a

laminar flow and an even distribution of the shielding gas.
The conical nozzle can be used if the following conditions are

met:
■ cw laser device
■ Pulsed laser device
■ Focal length of lens f = 200 mm
2
3
1
0031-50-S
1 Conical nozzle, rotatable 2 Conical nozzle, left 3 Conical nozzle, right

Fig. 2-38

Welding application The conical nozzle allows a laminar gas supply for large surfa-
ces with low radiation power and welding speed. The conical
nozzle ensures an even distribution of the shielding gas at
points of difficult access.
Depending on the application, a distance of 8 - 12 mm at a 30°
to 50° angle to the workpiece is recommended.
5
4
6
7
3
2 8
0031-52-S
1 1
1 Nozzle locking screw 6 Holding plate

2 Holder locking screw 7 Fastening screws extension
3 Clamping jacket “short” (2°x)
4 Fastening screw clamping 8 Locking screw height (2°x)
jacket (2°x) 9 Locking screw distance (2°x)
5 Fastening screw cube (2°x)
Fig. 2-39
Conical nozzle, rotatable The rotatable conical nozzle may be mounted with the clamping
jacket (3) on the crossjet support TL or CJ in any position.
The distance to the focusing optics and the angle to the work-
piece can be adjusted as required (2 and 1).
Conical nozzle, left and right The conical nozzles left and right may be mounted with the hold-
ing plate (6) laterally on the cube (5) or on the extension
“short” (7).
The distance to the focusing optics and the workpiece and the
angle to the workpiece can be adjusted as required (8, 9 and 1).
Shielding gas hose The following shielding gas hose must be connected to the
screw joint of the conical nozzle:
External diameter: 6 mm
Internal diameter: 4 mm
Tab. 2-15

Other methods
If a very good and even covering of the material with shielding

gas is required, the use of a glove box is recommended. The
glove box encloses the working area completely and the shield-
ing gas cannot escape.
No shielding gas nozzles are required since the glove box is
completely filled with shielding gas.
4.5 Arrangement of the shielding gas

nozzles
For laser welding, a distinction is made between two welding

processes:
■ Thermal conduction welding
■ Deep welding
With thermal conduction welding, the material is melted at the
surface only. Welding seams of some tenth of millimeters depth
are produced. This method is especially common with pulsed
Nd:YAG laser
With penetration welding, however, very deep and very narrow
welds are produced. Penetration welding is done with Nd:YAG-
lasers in cw mode.

3 3
6
5
2
2
1 4 1 4
0015
1 Solid melt 5 Vapor Channel (keyhole)
2 Melting zone 6 Escaping metal vapor
3 Laser beam A Welding direction
4 Material
Fig. 2-40
Pulsed lasers
In order to obtain an optimal working result with a pulsed laser

device, the welding wire (if used) is supplied in most cases
through penetration (running ahead). The direction where the
shielding gas is supplied from can be freely selected.

1
2
0011
1 Wire 2 Shielding gas supply
Fig. 2-41
cw lasers
In order to achieve optimum results with cw laser devices, the

shielding gas is always supplied trailing and the wire supply (if
used) leading.
1
2
0010
1 Wire 2 Shielding gas supply

Fig. 2-42

Welding at edges
The nozzles of the shielding gas supply line must be arranged

in a way that a laminar, constant gas flow is produced. Espe-
cially welding at edges can cause swirls that move the oxygen
of the surroundings to the weld point. The material can already
react with the oxygen if the oxygen portion > 0.5 %.
If welding is performed on edges, a swirl of the gas flow can be
prevented by attaching a deflector.
3 3
4
2
1
0013
1 Workpiece 3 Laser beam
2 Deflector 4 Shielding gas nozzles
Fig. 2-43
4.6 Dosing shielding gas
Correct dosing of the shielding gas is important for getting an

optimal welding result. In the ideal case, the gas flows in a lami-
nar flow evenly over the processing point. If not enough shield-
ing gas is supplied, the protective effect is not sufficient and gas
or humidity from the air can reach the welding seam. Too much
shielding gas causes swirls that lead air to the weld point.

0023
Turbulent gas flow: High gas pressure, air is Laminar gas flow: Low gas pressure; without
taken in. inflow of air
Fig. 2-44
The color of the welding seam allows a statement about the

amount of the used shielding gas.
From a gray discoloration of the welding seam can be con-
cluded that no shielding gas was used. If the welding seam yel-
lows, the dose must be optimized further. A high gloss seam is
produced when the shielding gas is dosed optimally.
0020
Weld seam: without shielding gas, gray discoloration of the Fig. 2-45
seam.

0022
Weld seam: yellow color zones in the seam (bright areas in Fig. 2-46
the picture); dosing must be optimized further.
Weld seam: shielding gas optimally dosed, even, high-gloss 0021

Fig. 2-47
seam.
A shielding gas nozzle with perlator ensures an even outflow of

shielding gas. The same effect can be created with steel wool in
the nozzle.

LASER
0014
Laminar flow Fig. 2-48
Crossjet For welding applications with a strong production of splashes

and vapor, a crossjet can be used. The crossjet must be
adjusted to allow the shielding gas to flow unaffected by the
crossjet gas.
Tip
With a simple test, it can be checked if the crossjet was
adjusted optimally.
Keep a paper strip over the workpiece and adjust the gas pres-
sure to such a level that the paper strip is not pushed down or
drawn in by the crossjet.
4.7 Effect of the shielding gas
The different shielding gases have different effects. They influ-

ence the form of the weld seam and can generate seam surfa-
ces which are smoother and glossier. The formation of pores in
the weld seam and spatter formation can be influenced by the
selection of the shielding gas.
The incoupling of laser light is deteriorated by a shielding gas!
Argon (Ar) Helium (He) Nitrogen (N2) without shielding

gas
Seam shape b b b b
b = width
t = depth t t
t t
Seam surface ++ + + -

Argon (Ar) Helium (He) Nitrogen (N2) without shielding
gas
Spatter + + 0 -
Pores ++ + + -
Incoupling laser light - - - +
Costs - - 0 +
Effect of the shielding gases: + = favorable, 0 = neutral, - = unfavorable Tab. 2-16
Note
must have been switched on briefly before starting and remain
switched on after finishing welding.

Chapter 3
Description
1 Models and options 3‐3

1.1 Minimum configuration 3‐3
1.2 Available modules 3‐4
2 Components 3‐7
2.1 Focusing optics module overview 3‐7
2.2 Requirements 3‐10
2.3 Plug receptacle 3‐12
2.4 Protective sleeve 3‐13
2.5 Collimation 3‐14
2.6 Motor-driven focal control (analog) 3‐16
2.7 Programmable motor-driven focus setting pro- 3‐17
cedure (PMF)
2.8 Pivot joint 3‐18
2.9 Dual focus optics 3‐18
and fixed distance between the focal
points
21-01-29-CRen 2019-03 Description 3‐1

Dual focus optics with variable splitting 3‐21
points
points
2.10 Connecting piece 3‐25
2.11 Observation optics 3‐27
2.12 Illumination module 3‐31
2.13 Interface for sensor module 3‐32
2.14 Lenses for welding 3‐32
Lens with exhauster 3‐38
Crossjet 3‐39
2.15 Line laser 3‐43
2.16 Compensation cassette 3‐44
2.17 Cutting optics 3‐46
2.18 Protective glass monitoring 3‐48
2.19 Connection plates 3‐49
2.20 Magnetic coupling 3‐51
2.21 Focusing optics examples 3‐52
3 Functional description 3‐59

3.1 Beam guideway of the laser light 3‐59
3.2 Beam guideway in the observation optics 3‐65
3.3 Connection to the laser device 3‐67
3‐2 Description 2019-03 21-01-29-CRen

1. Models and options
The focusing optics has a modular design. Various modular sys-

tem components can be combined, depending on the application.
Special applications may require special models.
1.1 Minimum configuration
3
4
5
0031-18-T
1 Plug receptacle 4 Lens
2 Collimation 5 Lens protection
3 Extension “short”
Minimum configuration of a focusing optics D70 with drawn- Fig. 3-1
in beam path
Extension “short” The collimation is connected to the lens (4) via the extension
"short" (3).
21-01-29-CRen 2019-03 Models and options 3‐3

1.2 Available modules
The modules available for the focusing optics D70 are listed
below:
■ Plug receptacle B
− for connecting an LLK-B laser light cable
− for connecting a TWIN LLK-B laser light cable
■ Plug receptacle D
− for connecting an LLK-D laser light cable
− Cooling sleeve for plug receptacle D
■ Collimation
− Collimation without defocusing
− Collimation with defocusing
− Special collimation 175 for TruDiode laser devices
− Cooling ring 36 for collimation with defocusing
− Cooling ring 100 for collimation without defocusing
■ Pivot joint for turning the optics below the flange surface
■ Motor-driven focus setting procedure
■ Programmable motor-driven focus setting procedure
■ Dual focus optics
− Dual focus optics with fixed splitting ratio and fixed point
spacing
− Dual focus optics with variable splitting ratio and fixed
point spacing
− Dual focus optics with fixed splitting ratio and variable
point space, already contains the collimation and the
plug receptacle.
− 0° cooling plate for variable dual focus optics
− 90° cooling plate for variable dual focus optics
■ Connecting pieces
− Extension “short”
− Empty cube
− 90° cube without observation optics
− 0° cube for attachment of observation optics
− 90° cube for laser beam deflection by 90° and viewing
optics attachment.
− 2 x 90° double deflection for deflection of the laser beam
and mounting of the observation optics.
− Cooling plate for empty cube, 0° cube, 90° cube and
2 x 90° double deflection.
■ Lens for welding applications
− Lens 100 A, 150 A, 200 A
− Lens 100 AQ, 150 AQ, 200 AQ with exhauster
− Lens 100 AQ VIS, 150 AQ VIS, 200 AQ VIS, 280 Q
VIS, 560 Q VIS for illumination module
− Cooling ring for lens
3‐4 Models and options 2019-03 21-01-29-CRen

− Lens protection
− Lens protection Q
− Lens protection Q VIS for illumination module
− Crossjet VIS for illumination module
− Crossjet TL VIS for illumination module
− cartridge module
− Cassette module redesign
− Cassette module plate
− Cassette module plate gas
− Crossjet CM CJ for cassette module
− Shielding gas supply for Crossjet CM CJ
− Crossjet CM TL for cassette module
− Optimized crossjet CM TL for cassette module
− Shielding gas supply for Crossjet CM TL
− MDE nozzle for crossjet TL
− Crossjet cooling plate 280-600
■ Cassette for set-up mode with pilot laser
− Compensation cassette (PCC) for cassette module
■ Cassette for adjusting the focal position
− Teach cassette (TAC) for cassette module
■ Shielding gas supplies
− Single tube
− Multiple pipe
− Linear nozzle
− Conical nozzle
■ Cutting optics
− Adapter for cutting optics
− Cutting optics 100 AQ, 150 AQ
− High pressure cutting optics 100 AQ, 150 AQ, 200 AQ
■ Viewing optics
− Observation optics for eyepiece or camera, straight
− Observation optics for eyepiece or camera, rotatable
− Eyepiece
− Adapter for camera
− Illumination module (see operating instructions for illumi-
nation module D70 when operated with camera).
■ Sensor module for process monitoring
− Interface for sensor module
■ Line laser
■ Connection plates for robots
− DIN-ISO connection plate
− Robot plate KR30
■ Magnetic coupling
■ LLK protective sleeve
■ Adhesive tape, 19 mm
21-01-29-CRen 2019-03 Models and options 3‐5

The description of the individual components is subdivided into:
■ the shielding gas supply lines (see chapter “Mounting and
installation”).
■ all other components.
3‐6 Models and options 2019-03 21-01-29-CRen

2. Components
In the following section you will find:

■ the various demands on the focusing optics.
■ a description of the various focusing optics modules.
2.1 Focusing optics module overview
Modular system Focusing optics are composed of modules according to the

requirements of the respective processing task.
The following figures show the most important modules available
for focusing optics.
21-01-29-CRen 2019-03 Components 3‐7

Modules for 0° focusing
optics
4 5 10
7 6
11
8
3 12
1 2
14
16 15
13
23
24 22 21 20 19 18 17
1 Motor-driven focus control with 9 Camera 17 Cutting optics

plug receptacle D 10 Observation optics, can be 18 Lens with exhauster
2 Programmable motor-driven turned 19 Lens with crossjet CJ
focus setting procedure with 11 Observation optics, straight 20 Lens with cassette module and
plug receptacle D
12 Eyepiece crossjet CJ
3 Dual focus optics
13 Interface for sensor module 21 Lens with cassette module and
4 Plug receptacle B crossjet TL
14 0° cube
5 Plug receptacle D 22 Focusing lens with cassette
15 Extension “short”
6 Cooling sleeve for plug recepta- module and optimized crossjet
16 Heat sink
cle D TL
7 Collimation 23 Lens with lens protection and
8 Cooling ring of the collimation cooling ring with MDE nozzle
24 Lens with lens protection
0° focusing optics module overview Fig. 3-2
3‐8 Components 2019-03 21-01-29-CRen

Modules for 90° focusing
optics
1 2
7 8
12 11
9
5
10
5
3 4
15 14 13
22
17 16
19
18
23 21 20
1 90° cube 9 Camera 17 Lens with exhauster

2 Heat sink 10 Dual focus optics 18 Lens with crossjet CJ
3 Interface for sensor module 11 Plug receptacle B 19 Lens with cassette module and
4 Observation optics, straight 12 Collimation crossjet CJ
5 Eyepiece 13 Plug receptacle D 20 Lens with cassette module and
crossjet TL
6 Observation optics, can be 14 Cooling sleeve for plug recepta-
turned cle D 21 Focusing lens with cassette
module and optimized crossjet
7 Programmable motor-driven 15 Cooling ring of the collimation
TL
focus setting procedure with 16 Cutting optics
plug receptacle D 22 Lens with lens protection
8 Motor-driven focus control with 23 Lens with lens protection and
plug receptacle D cooling ring
90° focusing optics module overview Fig. 3-3
Most of the focusing optics modules can be used for 0° and 90°
versions.
21-01-29-CRen 2019-03 Components 3‐9

2.2 Requirements
Focal lengths Depending on the machining task, lenses with various focal
lengths are used. The focal length of lens has an effect on
■ the working distance between lens and workpiece.
■ the beam diameter and thus the power density at the
machining point.
■ the depth of focus and consequently on the machining depth
in the workpiece.
Wavelengths The focusing optics can be operated within different wavelength

spectrums. The individual optical components are provided with
adhesive labels that show the permissible wavelength spectrum.
TRUMPF
ct-00272
Cube 0° with adhesive label Fig. 3-4
The wavelength spectrum depends on the laser device to which

the focusing optics are connected.
Note
When the focusing optics is optimized for a specific wavelength
then a label displaying this wavelength is attached to the focus-
ing optics. In this case, the focusing optics must not be used
with any other wavelength. In other cases, the focusing optics
can only be used with a narrow band of wavelengths (1030 nm
to 1070 nm).
3‐10 Components 2019-03 21-01-29-CRen

Applications Focusing optics are used for:
■ Welding: Welding optics.
To avoid strong spatter while welding, the laser power
should be increased very gradually at the beginning, and
reduced very gradually at the end of the welding seam. This
is done by programming a start and end ramp for the laser
power in the laser program (see the TruControl 1000 soft-
ware manual, doc. no. 10-06-80-A1-CR).
■ Cutting: Cutting optics.
Cutting gas must be supplied for cutting tasks.
Interaction with the material Various interactions with the material may arise during cutting or
welding applications, depending on the workpiece material:
■ If the laser beam is strongly reflected by the workpiece, suit-
able measures for cooling the focusing optics have to be
taken (e.g. copper and aluminum alloys).
■ In case of increased metal deposits on the lens protection,
the focusing optics can be equipped with an exhauster or a
crossjet.
Observation methods Focusing optics offer different observation methods:

■ eyepiece for observing the machining point, mostly for adjust-
ment work.
■ CCD camera for a permanent observation of the machining
process.
Geometry Focusing optics are available in two designs:

■ straight version (0°).
■ angled version (90°).
Two weld points, Dual focus optics can be used for simultaneous application of
two weld seams two weld points or two welding seams next to each other.
The dual focus optics is available in different versions:

■ Dual focus optics with fixed splitting ratio and fixed point
spacing.
■ Dual focus optics with variable splitting ratio and fixed point
spacing.
■ Dual focus optics with fixed splitting ratio and variable point
spacing.
Supplying two laser devices Two laser devices can be connected to one focusing optics by
using the plug receptacle TWIN LLK-B, if a very high power den-
sity is required on the machining point.
Special constructions Special constructions are possible for special applications.
21-01-29-CRen 2019-03 Components 3‐11

2.3 Plug receptacle
1 2
3
5 4
7
6 5
2
ct-00278
4
9 8
1 Plug receptacle B 6 Plug receptacle D
2 Adjustment screw (4x) 7 Retaining ring
3 Locking screw 8 Dust cover
4 Cooling water connection, sup- 9 Push-button
ply
5 Cooling water connection return
Fig. 3-5
Laser light is generated in the laser device and coupled into the
laser light cable.The plug receptacle holds the optical plug of
the laser light cable and aligns the fiber end faces with the axis
of symmetry of the optical unit.
The plug receptacle of the focusing optics is available in three

versions:
■ Plug receptacle B for LLK-B.
■ Plug receptacle for TWIN LLK-B.
■ Plug receptacle D for LLK-D.
Note
The connection hole must be sealed with the sealing plug
intended for this purpose if no laser light cable is plugged in.
When replacing the LLK, make sure that the plug receptacle lies
horizontally. This is to prevent dirt from entering the opening of
the plug receptacle from above.
3‐12 Components 2019-03 21-01-29-CRen

Cooling unit Cooling of the plug receptacle is required for a mean laser
power of more than 600 W. The cooling connections are always
prepared for connection of the cooling unit.
Special features of the ■ The plug receptacle for TWIN LLK-B may be used only:
TWIN LLK-B − for 0° focusing optics.
− without observation.
− with connecting piece: empty cube.
■ If you would also like to use the plug receptacle for TWIN
LLK-B for 90° focusing optics or with observation optics, con-
tact TRUMPF.
Note
The plug receptacle for TWIN LLK-B must not be used for cut-
ting optics and dual focus optics.
2.4 Protective sleeve
1 2
0260-54-T
1 Velcro fastener 3 Sealing plug for plug receptacle

2 Adhesive tape (stock) 4 Protective cap for LLK plug
Fig. 3-6
The protective sleeve encloses the plug receptacle of the focus-

ing optics and protects it from dirt.
To protect the LLK from dirt, TRUMPF recommends sealing the
disconnection point between the LLK plug and the plug recepta-
cle of the focusing optics with adhesive tape (see chapter"Mount-
ing and installation").
21-01-29-CRen 2019-03 Components 3‐13

Note
For sealing the disconnection point, use exclusively PVC adhe-
sive tape, 19 mm, material no. 1420313.
Inside the protective sleeve, you will find a pocket where you
should keep the following objects:
■ Adhesive tape for sealing the disconnection point
■ Plug and protective cap for covering openings.
Note
Make sure that the Velcro fastener is always tightly closed over
the entire length of the protective sleeve during operation.
Tip
The Velcro fastener at the end of the protective sleeve can also
be used to additionally fix media hoses.
2.5 Collimation
0031-07-T
3 2 1
1 Scales 3 Counter ring

2 Set ring
Collimation Fig. 3-7
The collimation converts the conical laser beam coming out of

the laser light cable to a parallel beam.
Focusing optics D70 have a collimation unit with focal length
fc = 200 mm as standard. The focal length of collimation deter-
mines the dimensions of the focusing optics.
Set ring, scales and the counterring are provided only for colli-
mation units with defocusing unit.
3‐14 Components 2019-03 21-01-29-CRen

Note
For some laser device of the TruDiode series, a special collima-
tion having a collimation focal length fc = 175 mm is used. For
information on this special collimation, please contact TRUMPF.
Zero position When set to zero (arrow) and at a distance B between the
focusing optics and the workpiece adjusted according to the
dimensional drawing, the focal plane is exactly on the workpiece
surface.
Set ring The laser beam can be defocused by means of the set ring. By
defocusing the laser beam the focal point can be placed below
or above the workpiece surface to be processed while the work-
ing distance remains the same. The position of the focal point
can be read on the scale.
Counterring The counterring fixes the set ring in its current position.
Scales One scale each is provided for the focal lengths 100 mm,
150 mm and 200 mm. The shift of the focal point in mm can be
read on the scales, if the collimation is defocused (see chapter
"Adjustment work").
■ Positive values: Focal point is above the workpiece surface.

■ Negative values: Focal point is below the workpiece surface.
Cooling rings for collimation
1 2
0030-55-T
1 Cooling ring 36 2 Cooling ring 100

Cooling rings for collimation Fig. 3-8
Additional cooling of the collimation by means of a cooling ring

is required at an average laser power of more than 3 kW. The
cooling ring is slipped onto the collimation unit.
In the cooling circuit the cooling ring is always connected in
series downstream of the plug receptacle.
21-01-29-CRen 2019-03 Components 3‐15

Cooling ring 100 The cooling ring 100 is suitable for cooling a collimation without
defocusing.
Cooling ring 36 The smaller cooling ring 36 is used for cooling a collimation with
defocusing.
2.6 Motor-driven focal control (analog)
0031-62-T
Motor-driven focal control Fig. 3-9
The motor-driven focus control can be used instead of a stand-

ard collimation.
During the motor-driven focus setting procedure, the collimation
lens is moved by means of the motor. The focal position is
changed by shifting the collimation lens.
The motor-driven focus control is controlled with ±10 V by an
external control unit via an interface.
The motor-driven focus control is suitable especially for applica-
tions in processes which require frequent changes of the focal
position.
3‐16 Components 2019-03 21-01-29-CRen

Note
With a laser power of 8 kW and a time interval of 15 min, the
duty cycle must not exceed 75 % (approx. 11 min).
You can find further information in document no.: 22-50-01-A45-
CR which can be obtained from TRUMPF upon request.
2.7 Programmable motor-driven focus

setting procedure (PMF)
Fig. 3-10
The programmable motor-driven focus setting procedure can be

used instead of a standard collimation.
With the programmable motor-driven focusing, the collimation
lens is moved by means of the motor. The focal position is
changed by shifting the collimation lens.
The programmable motor-driven focusing is suitable especially
for applications in processes which require frequent changes of
the focal position.
The programmable motor-driven focusing is supplied via the
control of the laser device (via the IIO3 interface) and connected
21-01-29-CRen 2019-03 Components 3‐17

in terms of control system to the laser control system. The focal
position can be programmed via TruControl 1000 or defined via
fieldbus.
Note
With a laser power of 8 kW and a time interval of 15 min, the
duty cycle must not exceed 75 % (approx. 11 min).
You can find further information in document no. 22-50-01-A369-
CR, which can be obtained from TRUMPF upon request.
2.8 Pivot joint
0030-56-T
Pivot joint Fig. 3-11
Application The pivot joint is mounted between collimation and connecting

piece. This makes it possible to turn the optics below the flange
surface in any direction. When using a dual focus optics, the
two focal points can be turned on the workpiece.
Note
If cooled components are used after the pivot joint the turning
range is restricted by the length of the cooling hoses.
2.9 Dual focus optics
The dual focus optics divides the laser beam into two partial
beams. The lens focuses the two parts of the beam on different
points on the processing plane. This allows simultaneous appli-
cation of two weld points or seams next to each other.
3‐18 Components 2019-03 21-01-29-CRen

Various versions Dual focus optics are available in the following versions:
■ Dual focus optics with fixed splitting ratio and fixed distance
between the focal points.
■ Dual focus optics with variable splitting ratio and fixed dis-
tance between the focal points.
■ Dual focus optics with fixed splitting ratio and variable dis-
tance between the focal points.
Dual focus optics with fixed splitting ratio

0030-73-T
1 Label
Dual focus optics with fixed splitting ratio and fixed distance Fig. 3-12
between the focal points
Division of the power The dual focus optics with fixed splitting ratio and fixed distance
between the focal points divides the laser beam in two partial
beams of same power.
If the laser light cable was replaced, it may be necessary to
adjust the power splitting of the dual focus optics (see chapter
"Adjustment work").
21-01-29-CRen 2019-03 Components 3‐19

Location of the focal points
c b
a
0030-68-R
360°
Fig. 3-13
The dual focus optics used and the lens determine the distance
of the focal points to each other and to the center line.
The dual focus optics which suit your welding applications can
be obtained from TRUMPF.
A label on the bifocal optics provides specifies the distance a at
a focal length f = 100 mm.
For detailed information, please see the dimensional drawing of
your focusing optics and the data sheet 22-24-26-BC.
The focal points can be turned by 360° around the center line
(see chapter "Adjustment work").
3‐20 Components 2019-03 21-01-29-CRen

Dual focus optics with variable splitting
points
0030-74-T
1 Label
Dual focus optics with variable splitting ratio and fixed dis- Fig. 3-14
tance between the focal points
Division of the power For a dual focus optics with variable dividing ratio and fixed dis-
tance between the focal points the percentage of the partial
beams can be set within the limits of 30 % : 70 % up to 70 % :
30 % (see chapter "Adjustment work")
Location of the focal points
a
0030-75-R
90°
Fig. 3-15
The dual focus optics used and the lens determine the distance
of the focal points.
21-01-29-CRen 2019-03 Components 3‐21

The outer focal point can be turned by 90° around the center
line (see chapter "Adjustment work").
Dual focus optics with fixed splitting ratio

points
0030-76-T
1 Scale, distance between the focal points

Dual focus optics with fixed splitting ratio and variable dis- Fig. 3-16
tance between the focal points
Division of the power The dual focus optics with fixed splitting ratio and variable dis-
tance between the focal points divides the laser beam in two
partial beams of same power.
If the laser light cable has been replaced, it may be necessary
to adjust the power splitting of the dual focus optics (see chap-
ter "Adjustment work").
3‐22 Components 2019-03 21-01-29-CRen

Location of the focal points The distance of the focal points can be adjusted within the
adjustment range of the dual focus optics (see chapter "Adjust-
ment work").
A label on the dual focus optics provides specified the adjust-
ment range of the distance a with a focal length of lens
f = 100 mm.
The set distance of the focal points can be determined by using
the scale (1). The formula for determining the distance between
the focal points is:
SG-02003
Fig. 3-17
The formula for determining the scale interval is:
SG-02004
Fig. 3-18
FA Distance between the focal points [mm]

FA min Smallest possible distance between the [mm]
focal points if f = 100 (see label)
FA max Largest possible distance between the [mm]
focal points if f = 100 (see label)
S Scale interval [mm]
f Focal length of lens [mm]
Tab. 3-1
The focal length of lens and the desired adjustment range deter-
mine the position of the focal points in relation to the center line
of the lens. Dual focal optics are available with two possible
positions (see "Fig. 3-19", pg. 3‐24).
21-01-29-CRen 2019-03 Components 3‐23

c b
a
a
0030-85-T
360° 90°
Fig. 3-19

The focal points can be turned by 360° around the center line
(see chapter "Adjustment work").
Cooling An additional cooling unit is required for an average laser power

from 600 W. The type of the cooling unit depends on the focus-
ing optics design:
■ 0° cooling plate for a dual focus optics with fixed splitting
ratio and variable point distance when using a 0° focusing
optics.
■ 90° cooling plate for a dual focus optics with fixed splitting
ratio and variable point distance when using a 90° focusing
optics.
3‐24 Components 2019-03 21-01-29-CRen

6 6
5 1
5 1
7 2
3
4
0030-87-T
1 Return 5 Hose cooling plate - flange
2 90° cooling plate 6 Supply
3 Hose cooling plate - lens 7 0° cooling plate
4 Cooling ring for lens
Cooling plates for dual focus optics with a 0° focusing Fig. 3-20
optics (left) and a 90° focusing optics (right)
2.10 Connecting piece
A connecting piece is mounted between collimation and lens.

Two different connecting pieces are used, depending on design
and task of the focusing optics:
■ Extension “short”.
■ Empty cube.
■ 0° cube for attachment of an observation optics.
■ 90° cube for deflecting the laser beam by 90° and for attach-
ing an observation optics.
■ 2 x 90° double deflection for deflecting the laser beam and
for attaching an observation optics.
21-01-29-CRen 2019-03 Components 3‐25

Fastening methods Connecting pieces are used to fasten focusing optics to a sup-
port.
Separating plate and The 0° cube has a separating plate, the 90° cube has a deflec-
deflection mirror tion mirror. The 2 x 90° double deflection has two deflection mir-
rors.
The laser light or the visible light for observation is deflected in
the cubes or the double deflection.
1 2
0030-72-S
1 Laser beam path 3 Cube with separating plate 4 Cube with deflection mirror
2 Beam path for observation
optics
Beam path through separating plate and deflection mirror Fig. 3-21
2
ct-00219
1 Laser beam path 3 2 x 90° double deflection

optics
Beam path through 2 x 90° double deflection Fig. 3-22
3‐26 Components 2019-03 21-01-29-CRen

Cooling plate on cube
ct-00220
Cooling plate on cube Fig. 3-23
Starting from an average laser power of 8 kW, an additional

cooling unit is required. For cooling, a cooling plate is mounted
on the connecting piece.
In the cooling circuit, the cooling plate is always connected in
series downstream of the plug receptacle D.
Note
If, starting from an average laser power of 8 kW the 90° cube
or the 2 x 90° double deflection is used as the connecting
piece, it is not absolutely required to use the cooling plate.
2.11 Observation optics
The observation optics is the intermediate piece between sepa-

rating plate or deflection mirror on one side and eyepiece or
camera on the other side.
21-01-29-CRen 2019-03 Components 3‐27

4
1
0040-02-T
2 3 2
1 Eyepiece 3 Diaphragm lever

2 Observation optics 4 Camera
Observation optics Fig. 3-24
The viewing optics consists of

■ a filter keeping away the laser light.
■ a deflection mirror (90° version only).
■ a magnifying or demagnifying optics, if necessary.
The processing point can be observed by means of an eyepiece.
To allow a continuous observation of the machining process, a
camera which is connected to a monitor can be attached.
A larger or smaller reproduction of the machining point is possi-
ble with a magnifying optics or with a demagnifying optics.
The visible section of the processing point depends on the focal
length of the lens, the magnification β of the observation optics
and the camera used.
You can choose from two CCD cameras:

■ CCD camera (CCD chip 1/2'')
■ CCD camera (CCD chip 1/3'')
CCD chip 1/2'' Magnification

Focal length of lens β = 0.4 β = 1 β = 2
100 mm 16 mm x 12 mm 6.4 mm x 4.8 mm 3.2 mm x 2.4 mm
280 mm 44.8 mm x 33.6 mm 17.92 mm x 13.44 mm 8.96 mm x 6.72 mm
3‐28 Components 2019-03 21-01-29-CRen

500 mm 80 mm x 60 mm 32 mm x 24 mm 16 mm x 12 mm
Visible section of the processing point on a 1/2" camera (analog output) Tab. 3-2

Focal length of lens β = 0.4 β = 1 β = 2
Visible section of the processing point on a 1/3" camera (digital output) Tab. 3-3
The diaphragm lever can be used to adjust the illumination of

the picture field.
A laser protective filter, installed in the observation optics, pro-
tects the operator against emitted laser radiation.
1 2 3 4 5
6
TE-02013
1 Focusing optics 3 Digital Camera power supply 5 Panel PC

2 Digital Camera unit 6 Panel PC power supply unit
4 Gigabit Ethernet cable
Digital Camera System Overview, example with focusing optics D70 Fig. 3-25
21-01-29-CRen 2019-03 Components 3‐29

The Digital Camera System consists of the following compo-
nents:
Component Functions
Digital camera (2) Observation of the processing point
Digital camera power supply unit (3) Power supply for the digital camera
Gigabit Ethernet cable1(4) Transmission of the camera image from the digital camera to the panel
PC.
Panel PC (5) Display of the camera image
Power supply unit for Panel PC (6) Power supply for the Panel PCPower supply for the Panel PC
Gigabit Ethernet switch2 Switch for connection of multiple digital cameras to a Panel PC.
Actuator/sensor cable1, 2 Extension cable for the digital camera power supply.
Tab. 3-4
The digital camera is available in the following versions:
Designation Variant
TXG03 Monochrome, sensor size 1/3"
TXG03c (option) Color, sensor size 1/3"
TXG02 (option) Monochrome, sensor size 1/4"
Tab. 3-5
For further information about the observation optics, see the

"Digital camera system" assembly instructions, doc.no.: 22-50-12-
A1-AK and "TruControl 1000 module video app" software man-
ual, doc. no.: 22-50-12-A1-CR.
1 Available in different lengths.

2 Option, not shown
3‐30 Components 2019-03 21-01-29-CRen

2.12 Illumination module
SG-03004
Illumination module D70 Fig. 3-26
The illumination module serves for illuminating the machining

point on the workpiece and is only allowed for operation with a
camera.
The illumination module is designed for

■ manual operation
■ externally controlled operation (e.g. PLC).
In combination with the illumination module D70, broadband anti-
reflective coated lenses and protective glasses as well as a spe-
cial cube must be used in the focusing optics (VIS label).
For further information on the illumination module see operating
instructions for illumination module D70 when operated with a
camera.
21-01-29-CRen 2019-03 Components 3‐31

2.13 Interface for sensor module
0030-58-T
1 Safety screws
Interface for sensor module, example 90° Fig. 3-27
A sensor module for process monitoring is connected via this

interface. The sensor module detects the laser radiation
reflected by the workpiece and the radiation emitted from the
machining point.
There is no laser protective filter in the interface for the sen-
sor module. Therefore use of the eyepiece or camera at this
interface is not allowed. The interface is secured by way of
safety screws (hexagon socket screws with pin).
During operation of the focusing optics, the sensor module has
to be attached to the interface or the interface has to be pro-
tected against laser radiation emission by a sealing plug.
There is no laser protective filter in the interface. If you

WARNING use the interface without sensor module or sealing plug,
your eyes and your skin may be exposed to laser light!
Laser light can burn your skin. Direct or scattered laser
light can permanently damage your eyes.
Ø Never look into the interface.
Ø Use the focusing optics only if the interface is closed by a
sensor module or a sealing plug.
Ø Never attach eyepiece or cameras to the interface.
2.14 Lenses for welding
The lens focuses the collimated laser beam onto the workpiece
surface. This generates the high power density in the focal point
required for welding.
3‐32 Components 2019-03 21-01-29-CRen

Note
To avoid strong spatter while welding, the laser power should be
increased very gradually at the beginning, and reduced very
gradually at the end of the welding seam. This is done by pro-
gramming a start and end ramp for the laser power in the laser
program (see the TruControl 1000 software manual, doc. no.
10-06-80-A1-CR).
Focal length The focal length of lens determines the working distance.
The focal length of the lens and the focal length of the collima-
tor define together the image ratio. The fiber core diameter of
the laser light cable and the image ratio define the focal diame-
ter (see "Beam guideway of the laser light", pg. 3‐59).
3
2
0031-26-T
1
1 Lens protection 3 Lens

2 Cooling ring 4 Cooling water connections
Lens with lens protection Fig. 3-28
3 1
ct-00217
1 Lens 3 Cooling water connections

2 Redesign cassette module
Lens with Redesign cassette module Fig. 3-29
The lens is sealed towards the workpiece:

■ by means of a lens protection (see "Fig. 3-28", pg. 3‐33).
or
by means of a cassette module (see "Fig. 3-29", pg. 3‐33).
Lens protection, cartridge The lens protection or the cassette module contains a protective
module glass to protect the lens against dirt or damage.
During welding, material particles or material vapor may be
deposited on the protective glass. Cleaning or replacing the pro-
tective glass is necessary then (see chapter "Maintenance").
21-01-29-CRen 2019-03 Components 3‐33

Cleaning or replacing of the protective glass of the cassette
module is particularly easy and can be done without any tools
(see chapter "Maintenance").
Tip
TRUMPF recommends purchasing a second protective glass
cassette. This allows the cassette to be changed quickly and
then the protective glass to be cleaned or changed in a clean
environment.
Improved cassette module In the improved cassette module (also called "Redesign cas-
sette module"), the seal between the crossjet support and the
cassette housing has been improved compared with the previ-
ous cassette module. Moreover, a closed contour at the front
end improves the durability of the optics and the protective glass.
In addition, the purge gas inflow has been divided such that the
cassette compartment and the area below the protective glass
are flooded with purge gas. This prevents fouling on the inside
even when the cassette has been pulled out.
Additional protective glass If focusing optics are operated in a contaminated environment

(e.g. dust or oil mist), the focusing lens might get dirty while the
protective glass cassette is removed. In order to protect the
focusing lens in this situation, TRUMPF has provided an addi-
tional protective glass.
The additional protective glass can be retrofit for existing focus-
ing optics. It then protects the focusing lens, even when the pro-
tective glass cassette is not inserted or the lens protection is
screwed off.
Send the focusing optics to TRUMPF's Service department for
retrofitting. The address can be found on the first page of this
document.
Tip
TRUMPF recommends using this under unfavorable welding con-
ditions. Using the additional protective glass can reduce repair
costs since the focusing lens is protected by the additional pro-
tective glass.
Note
If a green sticker marked SG (stands for "Schutzglas"; Engl: pro-
tective glass) is affixed to the focusing lens, the lens is already
prepared for the additional protective glass and does not have
to be sent to TRUMPF for retrofitting. In this case, only the
retaining ring and, if not available, the tool for changing the addi-
tional protective glass must be ordered.
3‐34 Components 2019-03 21-01-29-CRen

Marking on the lens Fig. 3-30
The additional protective glass is installed in front of the focus-

ing lens and protects this from contamination, even if the protec-
tive glass cassette is not inserted or the lens protection is
screwed off.
ct-00288
4 3
5
1 Focusing lens 4 Additional protective glass

2 Insert for protective glass 5 Holders for clamping ring
3 Clamping ring
Additional protective glass for protective glass cassette Fig. 3-31
The additional protective glass (4) is held by a clamping ring (3)

in the insert for the additional protective glass (2).
21-01-29-CRen 2019-03 Components 3‐35

1
ct-00287
1 Additional protective glass 2 Clamping ring
Fastening of the additional protective glass Fig. 3-32
In order to mount or change the additional protective glass (1),

the clamping ring (2) is pressed into an oval shape with a tool
(arrow direction in left figure). This way, it can be inserted in the
mounting devices attached to the inert or be removed from this
again.
In the inserted state, the clamping ring is under mechanical ten-
sion, which generates a force on the protective glass via the
bevels and fixes this in place (arrow in the right figure).
The clamping ring is also pressed into an oval shape with the
tool to remove it. This way, it can be removed with the addi-
tional protective glass.
Note
The focal position can be extended by 0.5 mm by inserting the
additional protective glass.
Protective glass monitor If the focusing optics is equipped with a protective glass
monitor, the laser control unit will monitor the degree of contami-
nation of the protective glass during operation (see "Protective
glass monitoring", pg. 3‐48).
Proximity switch The cassette module is equipped with a proximity switch that
can be connected to the PLC. The proximity switch signals
whether a cassette has been inserted or not.
Different types of glasses Focusing lenses and cover slides with different types of glass
are used depending on the mean laser power and the applica-
3‐36 Components 2019-03 21-01-29-CRen

tion. Lens and lens protection or cassette module are named as
follows:
■ Average laser power < 600 W.
− Lens A (achromatic).
− Lens protection.
or
Cassette module with protective glass.
■ Average laser power > 600 W.
− Lens AQ (quartz lens).
− Lens protection Q.
or
Cassette module with protective glass Q.
■ If you use an illumination module, the glasses are addition-
ally provided with broadband anti-reflection coatings.
− Lens AQ VIS.
− Lens protection Q VIS.
or
cassette module with protective glass Q VIS.
Note
When using TruDiode laser devices, protective glasses with des-
ignation D55x1.5 T900-1080 Q are required.
Cooling unit For a mean laser power of 600 W and more, the lens has to be
cooled.
For the lenses equipped with lens protections, a cooling ring is
pushed onto the lens.
In case of lenses equipped with cassette modules, the connec-
tions for the cooling unit of the lens are situated on the cassette
module.
The cooled components are connected in series in the cooling
circuit. The cooling water flows through the parts in the following
order: plug receptacle - collimation cooling ring – lens/cassette
module cooling ring.
The hoses are arranged so that the supply hose first leads to
the plug receptacle (see "Fig. 3-33", pg. 3‐38).
21-01-29-CRen 2019-03 Components 3‐37

1 1
6 6
2
2
3
3
4 4
7
5
0031-28-T
9 8
1 Supply 6 Return
2 Connecting hose 7 Lens
3 Cooling ring for collimation 8 Cassette module
4 Connecting hose 9 Lens protection
5 Cooling ring for the lens
Hose installation if cooling rings and a cassette module are Fig. 3-33
used (examples)
Lens with exhauster
Certain machining tasks require an exhaustion of particles or

vapors coming out of the material, to reduce contamination of
the protective glass and of the machining area. Lenses with an
exhauster are available for this.
3‐38 Components 2019-03 21-01-29-CRen

1 2
0030-60-T
3
1 Exhaust air connection 3 Workpiece

2 Supply air connection
Lens with exhauster Fig. 3-34
A lens protection with a protective glass and connections for air

supply and exhaust air are put on the lens.
Air supply The supply air is guided through a connection kit into the lens
protection. The supply air deflects material particles and material
vapors which are scattered in the direction of the protective
glass.
Exhaust air The exhaust air together with the air supply forms a closed vol-
ume flow. The metal particles and metal vapors are extracted
and filtered through the exhaust funnel. By this way, approxi-
mately 90 to 95 % of the impurities arising during the welding
process are extracted.
Shielding gas With a correct adjustment, the volume flow of air supply and
exhaust air does not reach the molten mass, thus also permit-
ting the use of shielding gas.
Basic circuit, Specifications on basic circuit and setting data are contained in
setting data the description of the connections of the lens with exhauster
(see chapter "Mounting and installation").
Crossjet
For welding applications with a strong production of splashes

and vapor, a crossjet can be used instead of the normal lens
protection.
21-01-29-CRen 2019-03 Components 3‐39

1
360°
2
5 5
4
0030-61-T
6 6
1 Lens 4 Supply air connection

2 Crossjet support with protective 5 Shielding gas supply
glass 6 Workpiece
3 Crossjet CJ
Lens with crossjet CJ Fig. 3-35
10 1 10 1 10 1
2 2
2
3 3
3
4 4
7 7 9 7 4
6
6 6
ct-00268
5 5
8
1 Lens 5 Coaxial MDE nozzle 9 Shielding gas connection

2 Cassette module 6 Crossjet TL 10 Connection for purging gas and
3 Purge gas ring 7 Supply air connection MDE nozzle
4 Adapter TL 8 Shielding gas supply 11 Connection for supply air of
optimized crossjet TL
Focusing lens with crossjet TL and optimized crossjet TL (far left) Fig. 3-36
Crossjet support with The crossjet support has a varying length, depending on the
protective glass focal length. The crossjet support has the same protective glass
for protecting the lens as the normal lens protection.
Crossjet support for The crossjet support has a varying length, depending on the
Crossjet TL focal length.
Optimized crossjet TL In the case of the optimized crossjet, the crossjet receptacle
and spatter guard have been improved. The airflow, which is car-
ried off externally, is conducted more smoothly. In addition, a
3‐40 Components 2019-03 21-01-29-CRen

copper shield is installed to improve the air conduction and dust
protection.
Connection: The air supply connection with the connected flat nozzle is
located on the bottom side of the crossjet support.
The flat nozzle generates an air flow at right angles to the laser
exit port. The air flow deflects particles and vapors from the pro-
tective glass. Impurities on the protective glass are reduced.
The width of the flat nozzle varies depending on the focal length.
Air supply The air supply used is cleaned and dried compressed air.
Crossjet CJ Crossjet Crossjet Crossjet

TL 20 TL 30 TL 40
Slot width 20 mm 30 mm 40 mm
Pressure ≥ 5.0 bar 2.0 to 2.0 to 2.0 to
4.5 bar (rec- 4.5 bar (rec- 4.5 bar (rec-
ommended ommended ommended
3.5 bar) 3.5 bar) 3.5 bar)
Air con- approx. approx. 150 approx. 225 approx. 300
sumption 600 l/min – 300 l/min – 450 l/min – 600 l/min
Noise level > 90 dB(A) approx. 80 approx. 80 approx. 80
dB(A) dB(A) dB(A)
Compressed air Tab. 3-6
The compressed air used must comply with the specification

according to DIN ISO 8573-1:
■ Max. particle size 1 µm
■ Max. pressure dew point 7 °C
■ Max. oil concentration 1 mg/m3
Scavenging gas The purge gas ring is delivered together with the crossjet TL. It
supports the function of the crossjet TL in the following manner:
The purging gas is passed into the cassette compartment and
the area below the protective glass via the purge gas ring. From
there the purging gas flows outside and prevents particles from
entering. This reduces the contamination of the protective glass
in addition to the effect of the crossjet TL.
A coaxial MDE nozzle is mounted to the purge gas ring.
MDE nozzle The MDE nozzle is attached to the crossjet (MDE means metal
vapor effect).
During the laser welding process, the laser light may be
reduced or deviated due to the particles in the metal vapor
(plasma torch). This may lead to welding depth fluctuations and
to irregular weld surfaces.
To minimize this effect, TRUMPF has developed a special
coaxial metal vapor nozzle. Cleaned and dried compressed air
21-01-29-CRen 2019-03 Components 3‐41

according to DIN ISO 8573-1 is supplied toward the processing
plane via the connection for the MDE nozzle. The air flow of the
MDE nozzle eliminates the plasma torch.
ct-00299
1
Plasma torch with and without use of coaxial MDE nozzle Fig. 3-37
Pressure approx. 0.9 bar

Hose diameter 6 mm
Compressed air for purging gas and MDE nozzle Tab. 3-7
ct-00285
1 Purging gas connection 4 Lateral MDE nozzle

2 Connection for purging gas 5 Connection for lateral MDE
and MDE nozzle nozzle
3 Coaxial MDE nozzle
Connections to lateral MDE nozzle and coaxial MDE nozzle Fig. 3-38
Shielding gas The air flow at a right angle to the laser exit port does not influ-
ence the molten material if adjusted correctly, thus allowing work
with the shielding gas.
For operation with shielding gas, an inert gas supply must be
mounted to the crossjet TL.
For the multiple tube with lateral MDE nozzle, a lateral MDE
nozzle is mounted to the front tube of the multiple tube. In addi-
3‐42 Components 2019-03 21-01-29-CRen

tion to allowing shielding gas to be used, it also makes it possi-
ble to reduce the metal damping effect.
Shielding gas Application-related (see "Using

shielding gas", pg. 2‐41)
Consumption approx. 15 l/min – 25 l/min
Tab. 3-8
Note
must remain switched on for about 3 seconds before starting
and after finishing welding.
2.15 Line laser
SG-03005
Line laser Fig. 3-39
The line laser together with the pilot laser are used for adjusting
the working distance in the set-up mode.
Depending on the arrangement of the observation optics, the
line laser is mounted either to the 0° cube or the 90° cube.
Before it is possible to use the line laser for adjusting the work-
ing distance, it has to be adjusted (see chapter "Adjustment
work", section "Adjusting the line laser").
21-01-29-CRen 2019-03 Components 3‐43

The following power supply options are possible:
■ Connection to 230 V by means of a 7 m cable with power
supply unit.
■ Connection to 6 V - 30 V of an external control unit using a
cable with cable ends.
2.16 Compensation cassette
Working laser and pilot laser have different focal positions with-
out the compensation cassette. The compensation cassette con-
tains a compensation lens that adapts the focal position of the
pilot laser in Z direction to the focal position of the working laser.
The focal point of the pilot laser then lies in the same plane as
the focal point of the working laser.
Note
Using the compensation cassette only makes sense if the light
path the focusing optics belongs to contains a shutter switch
with pilot laser.
The compensation cassette cannot be used in connection with a
laser device of the TruDiode series.
For information on your laser device, please contact TRUMPF.
1 1 4
3 3
ct-00214
2
Δz
1 Cassette module with protec- 3 Beam cone pilot laser

tive glass cassette 4 Compensation cassette
2 Working laser beam cone with
inserted protective glass cas-
sette
Offset of pilot laser and working laser focal points Fig. 3-40
3‐44 Components 2019-03 21-01-29-CRen

1
ct-00210
2
1 Compensation lens 2 Compensation cassette

Compensation cassette Fig. 3-41
If you bought the compensation cassette later, the pilot laser of

your laser device has to be adjusted by a TRUMPF service engi-
neer.
For the set-up mode with pilot laser, the compensation cassette
is inserted into the cassette module instead of the protective
glass cassette. The pilot laser can be used together with the
inserted compensation cassette for the set-up in the x, y, and z
directions.
3 2 1
0031-39-T
1 Workpiece 3 Largest circle diameter of the
2 Smallest circle diameter of the pilot laser light
pilot laser light
Fig. 3-42
The light of the pilot laser appears as a circle on the workpiece.

At the smallest circle diameter, the focal plane is directly on the
workpiece surface. If the distance between the focusing optics
and the workpiece is changed, the circle on the workpiece
becomes larger and can form a ring.
Note
The compensation cassette may only be used in the set-up
mode. After completion of the set-up mode, the compensation
cassette must be removed from the cassette module and the
protective glass cassette must be inserted.
21-01-29-CRen 2019-03 Components 3‐45

Tip
Integrate the proximity switch of the protective glass cassette
into the safety circuit of the associated light path. This guaran-
tees that no welding application can be started without protec-
tive glass cassette (see chapter "Mounting and installation").
2.17 Cutting optics
For cutting of materials there is a special cutting optics with cut-

ting gas supply and with different nozzles available.
0030-62-T
3
1 Cutting gas supply 4 Cutting nozzle

2 Nose piece 5 Lens
3 Workpiece
Cutting optics Fig. 3-43
Focal lengths of the lenses The lenses of the cutting optics have the following focal lengths:
■ 100 mm
■ 150 mm
The lenses of the high pressure cutting optics have the following
focal lengths:
■ 100 mm
■ 150 mm
■ 200 mm
Protective glass The lens can be protected against soiling and damage by way
of a protective glass which is incorporated in the cutting nozzle.
3‐46 Components 2019-03 21-01-29-CRen

Nose piece The focused laser beam exits the cutting nozzle through the ori-
fice. The focal point here is approx. 0.7 mm below the orifice on
the workpiece. The material is molten in the focal point.
Cutting gas The cutting gas supplied under pressure also exits through the
nose piece. Due to the high outgoing speed of the cutting gas
and the small distance to the workpiece, metal particles will be
swept away from the molten material. This creates the cutting
gap in the workpiece.
The cutting gas type used depends on the application. There is

a differentiation between two applications:
■ Flame cutting using oxygen for mild steel
Cutting gas pressure 0.5 to 5 bar
■ Fusion cutting using nitrogen for stainless steel
Cutting gas pressure 3 to 25 bar
High-pressure cutting optics The high-pressure cutting optics does not have only one but
three cutting gas supplies on the cutting nozzle. This ensures
sufficient gas throughput even with a high gas counterpressure.
Effects on the practical The smaller the working distance from cutting nozzle to the
work workpiece, the more metal particles are swept away from the
molten material. But the working distance must be adjusted
large enough to avoid collision of the cutting nozzle with the
workpiece.
The focal point should be below the workpiece surface with
increasing cutting depth and V-shaped cut surface.
Note
Cutting optics cannot be used together with dual focus optics or
the plug receptacle TWIN LLK-B.
21-01-29-CRen 2019-03 Components 3‐47

2.18 Protective glass monitoring
1 2
ct-00221
5
1 Holder for protective glass 4 Evaluation electronics for the
monitor protective glass monitor
2 Lighting connection (X2) 5 Contact block connection for
3 Laser device connection (X1) the protective glass cassette
(X4)
Fig. 3-44
If the focusing optics is equipped with a protective glass

monitor, the laser control unit will monitor the degree of contami-
nation of the protective glass during operation.
The maximum allowed contamination of the protective glass is
defined by the monitoring limit value. The limit values are
defined by the operator depending on the application and
entered in the “Application data” window in TruControl 1000.
Detailed instructions on how to use the software can be found
in the "TruControl 1000 for CFO, RFO, D70" software manual,
doc. no.: 10-06-80-A3-CR.
Note
In order to be able to monitor the contamination of the protec-
tive glass, the monitoring function must be activated in
TruControl 1000. Further information on this subject can be
found in the "Monitoring and control functions" chapter of this
software manual.
Depending on the degree of contamination, one to four LEDs

will be lit. If the contamination of the protective glass exceeds
the admissible range, a message will be displayed on the
monitor of the operating unit. Simultaneously, all four LEDs will
be lit. In this case, cleaning or replacing the protective glass is
necessary (see chapter “Maintenance”).
3‐48 Components 2019-03 21-01-29-CRen

Note
When the measured value reaches the fault limit, the light path
will be disabled. To eliminate the fault, the protective glass must
be cleaned or replaced. After that, the light path can be enabled
again by pressing the Light path reset in the light path menu.
If the focusing optics is started following a fault message,

NOTICE without having eliminated the cause of the fault, laser light
may be emitted from the focusing optics for a few
milliseconds.
This uncontrolled welding may destroy the workpiece.
Ø Eliminate the fault on the focusing optics immediately.
2.19 Connection plates
The connection plates are used to mount the focusing optics to

robot hands.
SG-03006
DIN-ISO connection plate Fig. 3-45
According to DIN ISO 9409-1, the DIN-ISO connection plate is

provided with:
■ a centering unit D 31.5
■ a pitch circle TK ∅ 50 for M6 screws and pin ∅ 6.
21-01-29-CRen 2019-03 Components 3‐49

SG-03007
KR30 connection plate Fig. 3-46
The connection plate KR 30 has a pitch circle TK of ∅ 100 for

M8 screws and pins of ∅ 8.
3‐50 Components 2019-03 21-01-29-CRen

2.20 Magnetic coupling
5 1
SG-03008
1 Connection plate 4 Yoke plate with adapter plate

2 Fixing bolt 5 Catch bracket
3 Case
Magnetic coupling Fig. 3-47
The magnetic coupling serves to protect the focusing optics and

its attached components (e.g. gaz nozzles) from damage due to
collision when used on industrial robots.
The focusing optics is mounted on the yoke plate. The yoke
plate is held magnetically.
If a collision occurs, the yoke plate containing the focusing
optics becomes detached. The catch bracket prevents the focus-
ing optics from falling.
21-01-29-CRen 2019-03 Components 3‐51

Note
For use with the magnetic coupling, TRUMPF provides shielding
gas supplies in a stronger version. Further information can be
obtained from TRUMPF upon request.
2.21 Focusing optics examples
The following examples show some typical configurations of

focusing optics that are possible using the available components.
Dimensional drawings The configuration of your focusing optics is to be found on the

dimensional drawings, included in the delivery of your laser
device.
Please contact TRUMPF for further information on available
focusing optics.
360°
3 8
0030-63-T
2 9
1
1 Lens protection 6 Plug receptacle

2 Lens 7 Eyepiece
3 Extension “short” 8 Observation optics for eyepiece
4 Collimation 9 0° cube (separating plate)
5 Connections for cooling unit
Focusing optics, straight version (0°) Fig. 3-48
The figure shows two examples of straight (0°) focusing optics:

the one without and the other with observation optics and eye-
piece.
3‐52 Components 2019-03 21-01-29-CRen

1
2
11 3
1
2
4
10
5
360°
XXXXXXX
9 6
XXX 8
7
ct-00201
1 Cooling unit connections for 7 Cassette module

plug receptacle D 8 Lens
2 Collimation 9 Extension “short”
3 Collimation cooling ring connec- 10 Cooling ring for collimation
tions
11 Plug receptacle LLK-D
4 Camera
5 Observation optics
6 0° cube (separating plate)
The figure shows two examples of straight (0°) focusing optics

with cassette module: one without and the other with observa-
tion optics and camera.
21-01-29-CRen 2019-03 Components 3‐53

1
S/N zzzzz
4
5
8
10
0031-48-T
9
1 Connections for cooling unit 6 Camera

2 Plug LLK-D 7 Observation optics
3 Plug receptacle D 8 0° cube (separating plate)
4 Collimation 9 Lens
5 Cooling ring 10 Cassette module
The figure shows a straight (0°) focusing optics with cassette

module and the plug receptacle D.
In this example, the plug LLK-D, the plug receptacle D, the colli-
mation and the cassette module are cooled.
3‐54 Components 2019-03 21-01-29-CRen

1 Plug receptacle LLK-D 6 0° cube (separating plate)
2 Connections for cooling unit 7 Cassette module
3 Motor-driven focal control 8 Coaxial MDE nozzle
4 Camera 9 Crossjet
5 Observation optics 10 Connections for cooling unit
The figure shows a straight (0°) focusing optics with motor-

driven focus control, cassette module and crossjet TL.
21-01-29-CRen 2019-03 Components 3‐55

1 2
6 5 4
0030-64-T
9
1 Observation optics for camera 6 90° cube (deflection mirror)

2 Camera 7 Cutting gas supply
3 Plug receptacle 8 Cutting optics
4 Connections for cooling unit 9 Nose piece
5 Collimation
Focusing optics, angled version (90°) Fig. 3-52
The figure shows an angled (90°) focusing optics with cutting

optics and with a camera as observation unit.
1 2 3 4
5
0030-65-T
8 7 6
1 90° cube (deflection mirror) 5 Connections for cooling unit

2 Dual focus optics 6 exhaust air connection
3 Collimation 7 Lens with exhauster
4 Plug receptacle 8 Supply air connection
Focusing optics, angled version (90°) Fig. 3-53
The figure shows an angled (90°) focusing optics with dual

focus optics and with a lens with exhauster.
3‐56 Components 2019-03 21-01-29-CRen

1
2
3 4
5
11
10
9 6
0030-66-T
8
1 Observation optics for camera 7 Crossjet
2 Camera 8 Connection for compressed air
3 Cooling ring for collimation 9 Cooling ring for lens
4 Collimation 10 Lens
5 Plug receptacle B 11 90° cube (deflection mirror)
6 Connections for cooling unit
Focusing optics with crossjet Fig. 3-54
The figure shows an angled (90°) focusing optics with crossjet

and with a camera as observation unit. Collimation unit and lens
are cooled in this example.
21-01-29-CRen 2019-03 Components 3‐57

1 Plug receptacle D 7 Lens
2 Cooling sleeve for plug recepta- 8 Cassette module
cle D 9 Crossjet
3 Collimation 10 Coaxial MDE nozzle
4 Cooling ring of the collimation 11 MDE nozzle
5 Cooling plate 12 Camera
6 2 x 90° double deflection
Fig. 3-55
The figure shows a focusing optics with a 2 x 90°double deflec-

tion, crossjet and a camera as observation unit. The plug recep-
tacle, collimation unit, 2 x 90° double deflection and lens are
cooled in this example.
3‐58 Components 2019-03 21-01-29-CRen

3. Functional description
3.1 Beam guideway of the laser light
6
7
8
9
0030-12-T
10
1 Optical plug of the laser light 6 Lens

cable (LLK-B) 7 Focusing lens
2 End of the laser light cable 8 Lens protection
3 Plug receptacle 9 Focal point
4 Collimation 10 Workpiece
5 Collimation lens
Focusing optics, schematic diagram Fig. 3-56
Beam guidance In case of a beam guidance through the laser light cable, a con-
ical laser beam comes out of the end of the laser light cable.
21-01-29-CRen 2019-03 Functional description 3‐59

The collimation lens converts this beam into a parallel beam.
The focusing lens focuses the laser beam onto the workpiece.
Focal length of collimation The focal length of the collimation unit fc determines the dis-
tance between the fiber end of the laser light cable and the colli-
mation lens. Focusing optics D70 have a collimation unit with a
focal length fc = 200 mm as standard.
Note
For some laser device of the TruDiode series, a special collima-
tion having a collimation focal length fc = 175 mm is used. For
information on this special collimation, please contact TRUMPF.
Focal length of lens The focal length of lens f determines the distance between
focusing lens and focal point.
Lenses with the following focal lengths can be used in the focus-
ing optics D70:
■ f = 600 mm.
■ f = 500 mm.
■ f = 400 mm.
■ f = 300 mm.
■ f = 200 mm.
■ f = 175 mm.
■ f = 150 mm.
■ f = 100 mm.
For information on special focal lengths, please contact
TRUMPF.
3‐60 Functional description 2019-03 21-01-29-CRen

1
dk
fc
2
3
0030-13-T
d0f
1 Optical fiber 4 Observation

2 Collimation lens 5 Focusing lens
3 Separating plate
Beam guideway in a 0° focusing optics Fig. 3-57
fc
2
1
3
dk
5
f
d0f
0030-14-T
1 Fiber 4 Observation
2 Collimation lens 5 Focusing lens
3 Deflection mirror
Beam guideway in a 90° focusing optics Fig. 3-58

Focal diameter The diameter of the focused laser beam at the smallest point
(waist) is called focal diameter d0f.
Fig. 3-59
d0f: focal diameter [mm]

f: Focal length of lens [mm]
fC Focal length of collimation [mm]
dk: Fiber core diameter [mm]

Reproduction ratio The ratio between the focal length f of lens and the focal length
fc of collimation is called aspect ratio β.
Fig. 3-60
β: Aspect ratio
β > 1 means that d0f > dk
β = 1 means that d0f = dk
β < 1 means that d0f < dk
Beam parameter product The beam parameter product (SPP) is a measure of the beam
quality and the focusing ability of a laser beam. The smaller the
beam parameter product, the better the beam quality. The beam
parameter product is determined by the laser property and the
connected laser light cable (LLK). It is constant for a laser
arrangement and is defined by:
SR-90252
1 1
SPP = ØLLK • ΘLLK = d0f • Θf = const. [mm • mrad]
4 4
Fig. 3-61
ΘLLK: Beam divergence [mrad], from LLK

∅LLK: Core diameter LLK [mm]
d0f: Focal diameter [mm]
Rayleigh length The range in which the focal diameter d0f is increased to 2 · d0f
is called Rayleigh length. The Rayleigh length is defined as fol-
lows:
Depth of focus The length of the optical axis in the focus where the focal diam-
eter d0f changes only negligibly, is called depth of focus.

4
1 2 5
0030-15-T
1 d0 = Beam waist diameter 4 zs = Depth of focus [mm]
[mm], θ = divergence [rad] 5 d0f = Focal diameter [mm]
2 θf = Divergence of the focused
beam [rad]
3 f = Focal length of lens [mm]
Depth of focus of a laser beam Fig. 3-62
Effect on the practical use The highest power density of the laser beam is achieved in the
focal point. Position and diameter of the focal point as well as
the depth of focus depend on the focal length of the used lens.
Short focal lengths of lens show the following advantages com-

pared with long focal lengths of lens:
■ The focal diameter is smaller. This results in a higher power
density in the focal point.
Long focal lengths of lens show the following advantages com-

pared with short focal lengths of lens:
■ Larger working distance. By this, less soiling of the lens pro-
tection as usually. The power density on the processing
point will drop with increasing soiling. This diminishes the
processing quality.
■ The depth of focus is longer. This allows a larger working
distance range without changed machining results.
The processing task, the selected components and thus the
beam guideway of the laser light determine the working distance
between focusing optics and the workpiece.
As a result of the given focal diameter and depth of focus, the
working distance must be maintained, if high-quality results are
to be achieved.
Best processing results are achieved

■ with a focusing optics tuned to the processing task at hand.
■ with a correctly adjusted working distance.
■ with clean optical components
■ with workpieces which are clean at the processing point.

3.2 Beam guideway in the observation
optics
2 1
1
5
4
2
0030-69-S
1 Eyepiece (or camera) 3 Flange with protective filter 5 Deflection mirror
2 Observation optics 4 Separating plate
0° focusing optics (left) and 90° focusing optics (right) Fig. 3-63
ct-00219
1 Laser beam path 3 2 x 90° double deflection

optics
Beam path through 2 x 90° double deflection Fig. 3-64
For observing and adjusting the workpiece, a separating plate or

a deflection mirror is inserted into the beam guideway.
0° focusing optics For a focusing optics 0° for monitoring, a separating plate is

used. This separating plate allows the transmission of light hav-

ing the wavelength of the laser beam. The separating plate
deflects the visible light coming from the workpiece through the
lens into the observation optics.
90° focusing optics For a 90° focusing optics for monitoring, a deflection mirror is
used. This deflection mirror is transparent for visible light. Thus,
it allows the visible light coming from the workpiece through the
lens to enter the observation optics. The deflection mirror
deflects the light of the laser beam to the lens.
Focusing optics with For a focusing optics with 2 x 90° double deflection for observa-
2 x 90° double deflection tion, two deflection mirrors are used. These deflection mirrors
are transparent for visible light. Thus, they allow the visible light
coming from the workpiece to enter the observation optics via
the lens. The deflection mirrors deflect the light of the laser
beam to the lens.
Protective filter The observation optics is provided with a protective filter to

avoid laser light being emitted from the observation optics.
Eyepiece or camera An eyepiece or a camera can be attached to the observation

optics.
The eyepiece is used for adjusting and watching the machining
point before or after the machining process.
The camera is used for adjusting and watching the machining
point also during the machining process.
The operating manual of the manufacturer contains information
about the camera.
Cross hairs The eyepiece contains crosshairs for aligning the focusing optics
to the processing point. The setting of the focusing optics is
described in "Setup" Chapter.
Note
If a camera is used to adjust the viewing optics, an additional
cross-hairs generator is required.

3.3 Connection to the laser device
0030-08-T
1 Cooling water hose – supply 3 Laser light cable (LLK-B)
2 Cooling water hose – return
Focusing optics connected to a laser device (diagram) Fig. 3-65
Laser light Laser light is generated in the laser device and coupled into the
laser light cable.

Chapter 4
Adjustment work
General notes on adjustment work 4‐3
1 Aligning the focusing optics 4‐4

1.1 Aligning the focusing optics 4‐4
2 Adjusting the focal position 4‐5

2.1 Setting zero position 4‐6
2.2 Taking objects out of the beam guideway 4‐6
2.3 Adjusting the working distance 4‐7
Determining the focal position with the 4‐9
working laser
Measuring the working distance 4‐10
Adjusting the focal position by means of 4‐12
the line laser
2.4 Adjusting the distance caliper 4‐12
2.5 Adjusting the line laser 4‐14
2.6 Defocusing the focusing optics 4‐16
Defocusing the focusing optics 4‐18
21-01-29-CRen 2019-03 Adjustment work 4‐1

2.7 Adjusting the focusing optics in the x-y direc- 4‐19
tion.
Adjusting the focusing optics, zero position 4‐20
Adjusting the focusing optics to a new 4‐20
workpiece
3 Adjusting the dual focus optics 4‐21

axis
3.2 Dual focus optics with variable splitting ratio 4‐22
Turning the focal point around the center 4‐23
line
points
Adjusting the distance between the focal 4‐26
points
axis
4 Adjusting the observation devices 4‐29

4.1 Adjusting the picture sharpness of eyepiece 4‐29
or camera
4.2 Adjusting the cross hairs 4‐31
4.3 Adjusting the illumination 4‐32
4‐2 Adjustment work 2019-03 21-01-29-CRen

General notes on adjustment work
The following conditions must be fulfilled:

■ The focusing optics must have been installed in the system.
■ The focusing optics must have been connected correctly to
the laser device by way of the LLK.
■ The necessary safety equipment must have been installed
and must be ready for operation.
■ Suitable laser safety glasses must be at hand.
■ There must be enough samples for the commissioning proce-
dure. A suitable workpiece holder for the samples must be
provided.
21-01-29-CRen 2019-03 Adjustment work 4‐3

1. Aligning the focusing optics
In almost all applications the optical axis of the focusing optics

is aligned with the processing plane.
0030-21-T
1 Guide edge on the connecting 3 Workpiece
piece
2 Guide edge on the lens protec-
tion
Aligning the 0° focusing optics with the processing plane Fig. 4-1
The 0° and 90° focusing optics have to be aligned in the same

way.
1.1 Aligning the focusing optics
Ø Align the guide edge of the connecting piece (1) vertically to

the workpiece (3)(see "Fig. 4-1", pg. 4‐4).
or
Ø Align the guide edge of the lens protection (2) in parallel
to the workpiece (3)(see "Fig. 4-1", pg. 4‐4).
4‐4 Aligning the focusing optics 2019-03 21-01-29-CRen

2. Adjusting the focal position
The highest power density of the laser beam is achieved in the

focal point. The position and the diameter of the focal point as
well as the depth of focus depend on:
■ the focal length of the used lens.
■ the core diameter LLC.
■ the focal length of collimation.
The deviation of the focal position Δz from the workpiece sur-
face has an important effect on the geometry of the weld point
or welding seam. The power density of the laser beam on the
workpiece depends on the position of the focal plane in relation
to the workpiece surface.
The focal position can be changed as follows:

■ Change of the clearance between focusing optics and work-
piece.
■ Displacement of the collimation lens by using the adjustment
ring on the collimation unit of the focusing optics .
Displacing the focal point by shifting the collimation lens in +
or – direction is called defocusing.
+ 2
3
Dz
Dz
0030-22-T
1 Collimation lens 3 Focal point

2 Lens
Effect of the collimation lens on the focal position Fig. 4-2
21-01-29-CRen 2019-03 Adjusting the focal position 4‐5

2.1 Setting zero position
Please see the following sections:

■ Taking objects out of the beam guideway.
■ Adjusting the working distance.
■ Defocusing the focusing optics.
■ Adjusting the focusing optics in the x-y direction..
With zero position and distance B between the focusing optics
and the workpiece adjusted according to the dimensional draw-
ings, the focal plane lies exactly on the workpiece surface.
0031-12-T
3
1 Collimation 3 Counter ring

2 Set ring
Fig. 4-3
1. Hold set ring (2) and turn counter ring (3) by one turn maxi-
mum.
2. Turn set ring and counterring simultaneously until the mark-
ing “0” on the set ring corresponds to the marking on the col-
limation (arrow).
3. Hold the set ring in position and tighten the counterring.
The focusing optics is in zero position.
2.2 Taking objects out of the beam

guideway
The laser beam exits the lens conically and achieves its highest
power density in the focal point.
4‐6 Adjusting the focal position 2019-03 21-01-29-CRen

Objects in the beam path cause
■ increased scattered light at the machining point.
■ risk of overheating of the object projecting into the beam
path.
■ backscattering of the laser light into the focusing optics. This
causes additional heating-up of the focusing optics and may
result in damage to the focusing optics and the laser device.
■ reduced power density in the focal point.
Condition
■ The connected laser device has been switched off and
secured against renewed switching on, e.g. by means of a
shackle padlock.
or
■ The light path to the focusing optics is blocked.
Fig. 4-4
Ø Remove all objects located in the beam guideway or projec-

ting into it.
2.3 Adjusting the working distance
For adjusting the working distance, the focal position of the

focusing optics must be known.
The following requires a new determination of the focal position:

■ a change of the focusing optics
■ a change of the clearance between lens and workpiece
■ a change of the lens.

Method Explanations
with observation optics or camera The working distance is changed until the workpiece sur-
face is sharply defined.
Note
This method is only possible if the observation optics or
camera were adjusted correctly.
according to dimensional drawing of the focusing Adjust the working distance according to distance B (see
optics dimensional drawing of the processing optics used).
Note
The defocusing must be in zero position.
with pilot laser of the laser device and compensation When using a compensation cassette, the working dis-
cassette tance is changed, until the minimum point diameter of
the pilot laser light on the workpiece is reached.
(applicable only to laser devices from December
2002; exception: laser devices of the TruDiode Note
series)
The pilot laser of the laser device is suitable for deter-
mining the focal position only if the compensation cas-
sette has been inserted into the cassette module. Work-
ing laser and pilot laser have different focal positions
without the compensation cassette (see chapter “Descrip-
tion”).
After completion of the set-up mode, the compensation
cassette must be removed from the cassette module
and the protective glass cassette must be inserted.
with working laser Small weld points are applied with different working dis-
tances to an anodized aluminum sheet. The smallest
spot diameter represents the working distance at which
the focal point is on the workpiece.
with line laser When using the pilot laser, the working distance is
changed until the spot of the pilot laser light coincides
with the line of the line laser light on the workpiece.
Note
This method requires correct adjustment of the line laser.
Methods for determining the focal position Tab. 4-1

Determining the focal position with the
working laser
Conditions
■ The focusing optics is connected to a laser device.
■ The laser device has been turned on.
If the laser beam exit and the processing point are not
WARNING placed in a protective cover, your eyes and your skin may
be exposed to laser light!
Laser light can burn your skin or irreparably damage your
eyes.
Ø Do not put your hands between focusing optics and work-
piece while laser light is emitted.
Ø Wear laser glasses suitable for the wavelength of the laser
light.
The following two tables contain guide values to be used for set-
ting the parameters for CW lasers and pulsed laser devices for
determining the focal position with the working laser.
Focal length of lens Pulse duration Power

100 mm 20 ms 0.25 kW
150 mm 30 ms 0.30 kW
200 mm 50 ms 0.30 kW
Guide values for CW lasers Tab. 4-2
Focal length of lens Pulse duration Power

100 mm 0.5 ms 0.5 kW
150 mm 0.6 ms 0.6 kW
200 mm 0.8 ms 0.7 kW
Guide values for pulsed lasers Tab. 4-3
The material no of the test plate is specified in the list of wear-

ing parts (see chapter "Maintenance", section "Wear parts").
1. Set the collimation unit of the focusing optics into zero posi-
tion .

B
2 1
0030-23-T
1 Anodized aluminum sheet B Space from lower edge of
2 Smallest weld point lens protection to focal plane
Determining the focal position with the working laser Fig. 4-5
2. Put an anodized aluminum sheet (1) on the working table.
3. Adjust distance B according to the dimensional drawing.
4. Apply several weld points on the anodized aluminum sheet.
There should be a space of approx. 6 mm between the weld
points . Change the distance between lens and workpiece
within a range from –3 mm to +3 mm.
–3 mm to +3 mm:
− for a focal length of lens of 150 mm and 200 mm in
steps of 0.5 mm.
− For a focal length of lens of 100 mm in steps of
0.25 mm.
With the smallest weld point (2), the focal point is directly on the
aluminum sheet. This identifies the focal position and by this the
actual distance between lower edge of the lens protection and
focal point for this focusing optics.
Measuring the working distance
The working distance indicates the vertical distance from the low-
ermost edge of the focusing optics to the workpiece.
If, e.g. for a welding optics the distance to the workpiece should
be measured exactly in the middle of the protective glass, the

space from lower edge of the lens protection to the protective
glass has to be added to the working distance between lower
edge of the lens protection and the workpiece.
Condition
secured against restart.
or
Note
Do not use pointed measuring instruments for measurements on
the protective glass to avoid scratches.
1 Protective glass B Space from lower edge of

2 Workpiece lens protection to focal plane
Δ Space from lower edge of
lens protection to lower edge
of protective glass
Working distance of a welding optics Fig. 4-6
Ø Measure the distance between the lower edge of the focus-

ing optics and the workpiece by means of a suitable measur-
ing instrument. Inside calipers can be used as measuring
instrument.
Tip
After having determined the correct working distance for your
focusing optics, adjust a caliper to the corresponding length .
This allows you to quickly set or check the distance from the
workpiece.

Adjusting the focal position by means of
the line laser
Condition
■ The line laser has been adjusted correctly (see "Adjusting
the line laser", pg. 4‐14).
1 3
0040-73-T
1 Line of the line laser (focal 3 Line of the line laser is located
plane not on the workpiece sur- on the point of the pilot laser
face)
2 Workpiece
Light of the pilot laser and the line laser Fig. 4-7
1. Switch on the pilot laser of the shutter switch.

2. Switch on the line laser.
3. Change the working distance until the line of the line laser
coincides exactly with the point of the pilot laser (3).
The focal plane of the working laser is now exactly on the
workpiece surface.
4. Switch off the line laser.
Switch on the line laser in set-up mode only, switch it off before
starting welding operations.
2.4 Adjusting the distance caliper
TRUMPF offers two distance calipers as accessories:

■ Caliper, adjustable from 69 to 235 mm
■ Caliper CM TL for a focusing optics with cassette module
and crossjet TL

■ Slotted screwdriver
■ Hexagon head screwdriver, 90°, 2.5 mm

Caliper L69-235
3
4
0031-55-T
1 Tip 1 (69 – 128 mm) 3 Sleeve
2 Locking screw (3 x) 4 Tip 2 (178 – 235 mm)
Fig. 4-8
1. Loosen the clamping screws (2).

2. If necessary, shorten the tip 2 (4) to the desired length.
3. Insert the appropriate tip 1 or 2 (1 or 4) into the sleeve (3).
4. Position the caliper between the focusing optics and work-
piece at an easily accessible point where the working dis-
tance can be adjusted or checked.
5. Screw in the clamping screws by hand and tighten them
carefully with a screwdriver.

Caliper CM TL
ct-00279
1 Crossjet TL or optimized cross- 3 Locking screw 4 Tip
jet TL
2 Spatter guard
Fig. 4-9
6. Pull the spatter guard (2) evenly off of the crossjet TL or

optimized crossjet TL(1) by hand.
7. Loosen the locking screw (3).
8. Push the CM TL distance gauge onto the crossjet TL or opti-
mized crossjet TL from below until it snaps in on both sides.
9. Position the tip (4) on the workpiece surface.
10. Tighten the clamping screw.
2.5 Adjusting the line laser
Condition
■ The working distance has been set correctly (e.g. by welding
a focus series on anodized aluminum sheet).

■ Slotted screwdriver

1
SG-03010
4
1 Line laser 4 Protective cover

2 Slotted screw 5 0° cube (separating plate)
3 Knurled screw
Fig. 4-10
1. Switch on the pilot laser of the shutter switch.

2. Switch on the line laser.
3. Loosen the slotted screw (2).
4. Turn the laser diode module until the line of the line laser
coincides exactly with the point of the pilot laser (3).
5. Tighten the slotted screw.
6. If necessary, reduce the line width using a knurled screw.
7. Switch off the line laser.
This completes the adjustment of the line laser.
1 3
2
0040-73-T
1 Line of the line laser (focal 3 Line of the line laser is located
plane not on the workpiece sur- on the point of the pilot laser
face)
2 Workpiece
Light of the pilot laser and the line laser Fig. 4-11
Tip
The easiest way of line laser adjustment is when using a cam-
era for viewing.

2.6 Defocusing the focusing optics
The machining task can require a movement of the focal point

into or away from the workpiece.
For collimations with set ring the laser beam can be defocused
by placing the focal point above the surface of the workpiece or
into the workpiece:
■ without changing the working distance between the focusing
optics and the workpiece
■ without change in the picture sharpness for eyepiece or cam-
era.
f=100 f=150 f=200

-2 -4,4 -8
-1 -2,2 -4
0 0 0
+1 +2,2 +4
+2 +4,4 +8
0031-13-T
Scales on the collimation unit Fig. 4-12
Scales The three scales on the collimation apply to focal lengths of

lens f = 100 mm, f = 150 mm and f = 200 mm. The shift in
focal position Δz can be read in mm on the respective scale on
the top edge of the set ring (arrow).
The top edge of the set ring (arrow) lies on the Δz value by
which the focal position is moved with regard to zero position.

1
2
+
+ 3
0030-25-T
1 Set ring 3 Workpiece
2 Counter ring
Defocusing the focusing optics Fig. 4-13
Special focal length If you use a lens with a special focal length, you can approxi-
mately determine the displacement of the focal position Δz as
follows:
SG-02005
Fig. 4-14
f Focal length of lens [mm]

fc Focal length of collimation [mm]
Δs Adjustment range of the set ring [mm]
Δz Displacement of the focal position [mm]
Tab. 4-4
The adjustment range in mm can be read on the scale "f=200".

The maximum adjustment range of the set ring is ± 8 mm.

Defocusing the focusing optics
1
2
+
+ 3
0030-25-T
1 Set ring 3 Workpiece
2 Counter ring
Defocusing the focusing optics Fig. 4-15
1. Hold set ring (1) and turn counter ring (2) by one turn maxi-
mum.
2. Turn set ring and counterring simultaneously in the desired
direction.
The focal point is thus shifted towards the workpiece or
away from the workpiece (see "Fig. 4-13", pg. 4‐17). The
adjusted value can be read on the corresponding scale (see
"Fig. 4-13", pg. 4‐17).
Note
A complete turn of the set collar causes a shifting of the col-
limation lens by 1 mm (=1scale division).
3. Hold the set ring in position and tighten the counterring.

2.7 Adjusting the focusing optics in the
x-y direction.
The x-y direction of the laser beam in the focusing optics is set
exactly to ± 0.2 mm upon delivery by TRUMPF.
Note
After installation of the focusing optics in a system environment,
the zero point for the x-y direction has to be determined.
x
SG-01106
y
z
Focusing optics, X-Y direction Fig. 4-16

If the laser beam exit and the processing point are not
WARNING placed in a protective cover, your eyes and your skin may
be exposed to laser light!
Laser light can burn your skin or irreparably damage your
eyes.
Ø Do not put your hands between focusing optics and work-
piece while laser light is emitted.
Ø Wear laser glasses suitable for the wavelength of the laser
light.
Adjusting the focusing optics, zero position
Note
After installation of the focusing optics in a system environment,
the zero point for the x-y direction has to be determined.
1. Apply weld point.

2. Define the coordinates of this weld point as new zero posi-
tion for the X-Y direction in the system.
3. Align the cross hairs of the eyepiece or of the camera with
the center of the weld point.
Adjusting the focusing optics to a new

workpiece
Note
Adjusting the focusing optics by means of the pilot laser of the
laser device is not as exactly as the adjustment by means of
the cross hairs, since the pilot laser generates a relatively large
spot on the workpiece. The pilot laser is not suitable for adjust-
ing the working distance.
Ø Approach desired point on the workpiece in X-Y direction:

− by means of the pilot laser in the laser device
or
− by means of the cross hairs of the observation optics
or
− by means of the coordinate values for this point deter-
mined from the system data.

3. Adjusting the dual focus optics
3.1 Dual focus optics with fixed splitting

ratio and fixed distance between the
focal points
Turning the focal points around the center

axis

■ Crosstip screwdriver, 1 x 100
4
3
0030-78-T
2 1 2
1 Allen screw (4x) 3 Cover plate

2 Recessed head screw (2x) 4 Hole
Fig. 4-17
1. Slightly loosen the four Allen screws (1).

2. Unscrew two recessed head screws (2).
3. Remove cover plate (3).
4. Insert a pointed object (e. g. a small screwdriver) into one of
the holes (4) of the bifocal insert. The bifocal insert can be
freely turned.
5. Turn bifocal insert to desired position.
6. Retighten all four Allen screws (1).
7. Reattach the cover plate with the two recessed head
screws (2).
Adjusting the splitting ratio
After a replacement of the laser light cable, a test welding has

to be done to check whether the two partial beams have the
same power.
If the weld points or seams vary in size or depth, the splitting
ratio has to be readjusted.
21-01-29-CRen 2019-03 Adjusting the dual focus optics 4‐21

1
1
0030-77-T
1 Allen screw (4x)
Fig. 4-18
1. Slightly loosen four Allen screws (1) so that the bifocal insert
can be shifted.
2. Shift the bifocal insert by turning the opposite Allen screws
simultaneously.
3. Retighten all four Allen screws.
4. Carry out a test welding to check whether the two weld
points or seams have same size and depth.
5. If not, repeat the adjustment steps.
If required, you can find further information in document no.:
22-24-32-BJ, which can be obtained upon request from
TRUMPF.
3.2 Dual focus optics with variable

splitting ratio and fixed distance
between the focal points
The percentage of partial beams can be set within the limits

30 % : 70 % to 70 % : 30 %.

■ Fork wrench 7 mm
4‐22 Adjusting the dual focus optics 2019-03 21-01-29-CRen

0030-79-T
1
1 Counter nut 2 Allen screw

Fig. 4-19
1. Loosen the lock nuts ( 1).

2. Shift the bifocal insert by turning the Allen screw (2) until the
desired position is reached.
3. Retighten the lock nut (1).
If required, you can find further information in document no.:
22-24-32-BJ, which can be obtained upon request from
TRUMPF.
Turning the focal point around the center

line

■ Arbor 3.0 mm
Note
The outer focal point can be turned by 90° around the center
line.
To allow the outer focal point to be turned in another quadrant
around the center line, the fitting position of the dual focus
optics must be turned.
For more information please see dimensional drawing sheet 2 of
your dual focus optics.

2
0030-80-T
1
1 Allen screw 2 Hole

Fig. 4-20
1. Loosen the Allen screw (1).

2. Insert an arbor into the hole (2) and turn the bifocal insert
by the desired angle.
The outer focal point turns around the center line of the
optics at the same angle like the adjustment block. One
scale division is equivalent to one turn by 5° starting from
zero position (see dimensional drawing).
3. Retighten Allen screw (1).

3.3 Dual focus optics with fixed splitting
ratio and variable distance between
the focal points
Fig. 4-21

Adjusting the distance between the focal
points

■ Hexagon head screwdriver 3 mm
1 Scale, distance between the 3 Locking brake 5 Adjusting shaft, distance

focal points 4 Allen screw between the focal points
2 Reading mark for scale value 6 Locking screw for adjusting
shaft
Fig. 4-22
1. To release the locking brake (3), tighten the Allen screw (4)
by turning it clockwise.
2. To release the clamping of the adjusting shaft, loosen two
Allen screws (6).
3. Turn the Allen screw of the adjusting shaft (5) to adjust the
desired distance between the focal points.
4. To clamp the adjusting shaft, tighten two Allen screws (6)
5. To lock the brake (3), loosen the Allen screw (4) by turning
it counterclockwise until no more spring pressure acts on the
screw.
The point spacing becomes smaller by turning the adjusting
shaft clockwise.
The set point spacing can be determined by using the scale (1).
Formulas for calculation are to be found in chapter "Description".
A complete turn of the adjusting shaft changes the scale interval
by one scale division.

Turning the focal points around the center
axis

■ Hexagon head screwdriver, 90°, 3 mm
3 Locking brake 7 Adjusting shaft, turning the 8 Locking screw for adjusting
4 Allen screw focal points shaft
Fig. 4-23
1. To release the locking brake (3), tighten the Allen screw (4)
by turning it clockwise.
2. To release the clamping of the adjusting shaft, loosen two
Allen screws (8).
3. Turn the Allen screw of the adjusting shaft (7), to adjust the
desired position of the focal points.
4. To clamp the adjusting shaft, tighten two Allen screws (8).
5. To lock the brake (3), loosen the Allen screw (4) by turning
it counterclockwise until no more spring pressure acts on the
screw.
A complete turn of the adjusting shaft changes the position of
the focal points by 90°.
The rotational direction of the focal points around the center line
is contrary to the rotation of the adjusting shaft.

After a replacement of the laser light cable, a test welding has

to be done to check whether the two partial beams have the
same power.
If the weld points or seams vary in size or depth, the splitting
ratio has to be readjusted.

■ Hexagon head screwdriver, 90°, 3 mm
1
1
1
2
2
0030-84-T
1 Locking screw (4x) 2 Adjustment screw (4x)

Fig. 4-24
1. Slightly loosen the locking screws (1) (a quarter turn).

2. Turn two opposite adjusting screws (2). Unscrew one screw
only as far as the other one was tightened.
3. Tighen the locking screws (1).
4. Carry out a test welding to check whether the two weld
points or seams have the same size and depth.
5. Repeat the procedure, if the two weld points or seams do
not have the same size and depth.

4. Adjusting the observation devices
The activities which can be carried out at observation devices

are described in this section. You will learn how to:
■ adjust the picture sharpness of eyepiece or camera
■ adjust the cross hairs
■ adjust the illumination of the camera picture field.
Note
The camera or the eyepieces can be removed if they are not
needed during the machining process, in order to avoid contami-
nation. Seal the open interfaces with the plug included in the
delivery.
4.1 Adjusting the picture sharpness of

eyepiece or camera
The picture sharpness of eyepiece or camera has been adjusted

ex works. Carry out the following steps to improve the picture
sharpness, if necessary.
Condition
or

■ Hexagon screwdriver, 90°, 1.5 mm
Adjusting the cross hairs of Note

the eyepiece
When using an eyepiece for observing the processing point,
first adjust the cross hairs in the eyepiece to your eye.
1. Look through the eyepiece.
2. Turn setting ring on the eyepiece until the cross hairs are
sharply visible.
Adjusting the distance to Note

the workpiece
The viewing optics must be set with correctly adjusted dis-
tance.
21-01-29-CRen 2019-03 Adjusting the observation devices 4‐29

3. Adjusting the distance to the workpiece(see "Measuring the
working distance", pg. 4‐10) .
Adjusting the picture

sharpness
2
1
3 3 3 3
4
5 5 4
1 Eyepiece 4 Knurled screw

2 Camera 5 Set screw
3 Allen screws (2x)
Fastening of eyepiece and camera Fig. 4-25
4. Loosen two Allen screws (3) until the eyepiece or the cam-
era can be moved.
5. Loosen set screw (5) and screw in knurled screw (4) clock-
wise.
6. Look through the eyepiece.
or
Ø watch the monitor with the camera picture
7. Move the eyepiece or the camera until the machining point
is pictured clearly.
8. Keep this position and retighten the two Allen screws (3).
The adjustment of the picture sharpness is now fixed.
9. Completely unscrew the knurled screw (4) until it makes con-
tact with the eyepiece or the camera.
10. Retighten the setscrew (5) in order to fix the knurled screw.
Tip
If you now want to remove the eyepiece or camera and then
slide the eyepiece or camera completely towards the knurled
screw and fasten it, the picture sharpness will remain
unchanged.
4‐30 Adjusting the observation devices 2019-03 21-01-29-CRen

4.2 Adjusting the cross hairs
The cross hairs of the focusing optics have been adjusted to the
center ex works. Readjust the cross hairs when maladjusted.
Condition
or

2
1
3 3
4 4
1 Eyepiece 3 Set screw (4x)

2 Camera 4 Allen screws (4x)
Adjusting the cross hairs Fig. 4-26
1. Loosen each of the four Allen screws (4) by a quarter turn.

2. Slightly loosen the set screws (3) which are at a right angles
to the desired shifting direction.
3. Shift the eyepiece (1) or the camera (2) until the cross hairs
and center of the picture are aligned. Simultaneously turn
the opposite set screws.
4. Carefully tighten all four set screws.
5. Check the position again and correct it, if necessary.
6. Retighten all four Allen screws.
The cross hairs are fixed in the center of the picture.
21-01-29-CRen 2019-03 Adjusting the observation devices 4‐31

4.3 Adjusting the illumination
If a camera is used
If you use a camera, the illumination of the picture field can be
adjusted.
If an eyepiece is used
If you use an eyepiece, the diaphragm should always be open
completely . This will give you the maximum brightness.
Condition
or
2
1
3
3
1 Eyepiece 3 Diaphragm lever

2 Camera
Fig. 4-27
Ø With camera: Turn the diaphragm lever until the illumination

is adapted to the sensitivity of the camera.
or
Ø Eyepiece: Turn diaphragm lever completely to the left so
that the diaphragm is completely open.
4‐32 Adjusting the observation devices 2019-03 21-01-29-CRen

Chapter 5
Maintenance
1 General notes 5‐3
2 Material 5‐5
2.1 Wearing parts 5‐5
2.2 Optics cleaning kit 5‐6
2.3 Consumables 5‐7
2.4 Disposal 5‐7
2.5 Tools and additional equipment 5‐8
3 Laser light cable (LLK) 5‐10

3.1 Disconnecting the LLK from the focusing 5‐10
optics
4 Welding optics 5‐13

4.1 Cleaning the protective glass in the lens pro- 5‐13
tection
4.2 Changing the protective glass of the lens pro- 5‐14
tection
21-01-29-CRen 2019-03 Maintenance 5‐1

4.3 Cleaning the protective glass in the protec- 5‐16
tive glass cassette
tive glass cassette (protective glass cassette
NU (NU=groove ring), starting from Septem-
ber 2016)
tive glass cassette
4.6 Changing the additional protective glass 5‐22
4.7 Replacing the lens along with the cassette 5‐25
module
4.8 Changing a lens without cooling ring 5‐28
4.9 Changing a lens with a cooling ring 5‐30
4.10 Cleaning the splash guard 5‐32
4.11 Cleaning the shielding gas supply 5‐33
4.12 Changing the tubes of the multiple tube 5‐34
5 Welding lens for lens with exhauster 5‐37

5.2 Cleaning the whole lens protection 5‐41
6 Compensation lens of the compensation 5‐44

cassette
6.1 Replacing the compensation lens of the com- 5‐44
pensation cassette
7 Line laser 5‐46

7.1 Replacing the line laser 5‐46
8 Cutting optics 5‐48

8.2 Adjusting a cutting optics equipped with 5‐53
observation optics
Aligning the cross hairs with the beam 5‐53
center
8.3 Adjusting a cutting optics without observation 5‐56
optics
5‐2 Maintenance 2019-03 21-01-29-CRen

1. General notes
The correct maintenance is an important precondition for trouble-

free operation of the focusing optics and for the quality of the
working result.
The focusing optics has been designed to require little mainte-
nance.
Regularly check the condition of your focusing optics. Carry out
maintenance work as a precautionary measure when you detect
signs of wear or dirt.
Check regularly the laser light cable for damaged sheathing.
The laser light cable must be replaced in case of a damaged
sheathing.
Pay attention to the monitoring messages the connected laser
device indicates on the screen. They may give information on
necessary maintenance work.
While carrying out maintenance work on the laser device

DANGER you may have to deal with parts dangerous for persons
and material.
Improper or incautious procedures can cause injuries or
damages to property.
Ø Maintenance work may be carried out by trained personnel
only.
Ø Any work at the electrical equipment may only be per-
formed by a skilled electrician.
Ø Always observe the warning notes in these maintenance
instructions.
Ø Switch off the laser device before starting maintenance work.
Note
The connected laser device must be switched on during mainte-
nance work only if it is necessary for maintenance or control pur-
poses. You will be informed about this in the corresponding sec-
tions of this manual.
Treated, deionized water (DI water) is used as cooling

CAUTION water!
Cooling water can be aggressive against skin and textiles.
Ø Do not bring the cooling water in eyes, nose or mouth.
Ø Avoid that cooling water comes into contact with your cloth-
ing.
Ø The cooling water can be washed off with tap water.
Ø Wear protective gloves, safety glasses and protective cloth-
ing.
21-01-29-CRen 2019-03 General notes 5‐3

Maintenance of the focusing When processing material with a laser, particles or vapors may
optics be emitted from the surfaces of the workpieces, which will result
in a fog and a soiling on the protective glass or on other parts
of the focusing optics. A soiled protective glass diminishes the
laser power on the workpiece.
Regularly check the condition of the protective glass. Clean the
protective glass and other parts of the focusing optics if they are
visibly soiled.
The protective glass has to be replaced if it shows soil particles
burnt-in, which cannot be removed by cleaning it.
If you use a cutting optics, the nose piece of the cutting optics
must be checked at regular intervals and cleaned or replaced, if
necessary. After change of the nose piece the adjustment of the
cutting nozzle has to be checked and the cutting nozzle has to
be adjusted again, if necessary.
The following is described:

■ maintenance of the welding optics
■ maintenance of the crossjet
■ maintenance of the welding optics if a lens with exhauster is
used
■ maintenance of the compensation cassette
■ maintenance of the teach cassette
■ maintenance of the cutting optics including adjustment.
5‐4 General notes 2019-03 21-01-29-CRen

2. Material
2.1 Wearing parts
Designation Material No.

Lens protection with crossjet Protective glass T900-1080 Q 1584792
O-ring 52 x 1.5 1200874
O-ring 56 x 2.0 1200875
Air guiding plate CJ15 (f = 100 mm) 0561920
Lens protection Q VIS and Protective glass T900-1080 Q 1584792
crossjet TL VIS
O-ring 52 x 1.5 1200874
O-ring 56 x 2.0 1200875
Spatter guard F100 (f = 100 mm) 1225364
Spatter guard F200 (f = 175 mm und 1225415
f = 200 mm)
Spatter guard D21 (f = 280 mm) 1434455
Spatter guard D42 (f = 560 mm) 1304665
Shielding gas supply multiple O-ring 1313436
tube
Tube 118 mm 1314397
Tube 125 mm 1314395
Tube 133 mm 1314394
Tube 140 mm 1314392
Lens AQ with exhaust system Protective glass T900-1080 Q 1584792
O-ring 1200873
Cutting optics Protective glass 0766719
Set of seals 0766237
O-ring 0754031
Cutting nozzle 0.5 mm 0779798
Multihole nozzle 1.0 mm 0766713
High pressure nozzle 1.7 mm 0766715
Cassette module new (version Protective glass cassette CFO 50 NU 1903255
starting from September 2016) (NU=groove ring) (for protective glass monitoring)
Protective glass cassette BEO D70 TAC NU 2081061
(NU=groove ring)
O-ring 52 x 1.5 flap 1200874
Frame seal EPDM-60 for handle 2081062
Grooved ring with snap-in nose for flap 1273931
21-01-29-CRen 2019-03 Material 5‐5

Designation Material No.
Cassette module Protective glass T900-1080 Q 1584792
O-ring 52 x 1.5 flap 1200874
O-ring on handle 1684680
O-ring 50 x 2 flap 1684919
Cassette module VIS Protective glass T900-1080 Q 1584792
O-ring 52 x 1.5 flap 1200874
O-ring 50 x 2 flap 1684919
Crossjet CM TL Spatter guard F100 (f = 100 mm) 1225364
Spatter guard F200 (f = 175 mm und 1225415
f = 200 mm)
Spatter guard D42 (f = 280/560 mm) 1304665
Compensation cassette Compensation lens 1220925
Line laser Line laser with power supply unit 230 V 1381578
Line laser with cable ends 6 - 30 V 1381581
Protective cover 1381586
Test sheet Black anodized aluminum sheet (80 x 50 x 1) 1424450
Additional protective glass Tool for changing the additional protective glass 2228704
Clamping ring, additional protective glass 2079404
Insert, additional protective glass 2074514
Protective glass, e.g. T900-1080 Q 1584792
Tab. 5-1
Note
The additional protective glass must be suitable for the laser
wavelength of the used laser. Please use the same protective
glass as in the used protective glass cassette.
2.2 Optics cleaning kit
TRUMPF recommends using the optics cleaning kit available for

cleaning of optical components.
The optics cleaning kit can be obtained from TRUMPF. It has
the material no. 779603.
5‐6 Material 2019-03 21-01-29-CRen

TE-01606
Fig. 5-1
2.3 Consumables
For maintenance work on the focusing optics, you need the fol-
lowing consumables:
■ Lens cleaning paper or swabs to clean optical glasses (avail-
able from the photo shops).
■ Methanol as cleaning agent for optical glasses.
■ Isopropyl alcohol as a cleaning agent for plastic e.g. sealing
rings.
Methanol is inflammable and toxic when you inhale or

CAUTION swallow it.
Ø Keep methanol away from open fire and other ignition sour-
ces.
Ø Do not smoke.
Ø Supply sufficient fresh air.
Ø Do not inhale methanol vapor.
2.4 Disposal
Some maintenance work will produce waste material that must

be disposed of. Instructions for an appropriate disposal are
given in the corresponding sections.
21-01-29-CRen 2019-03 Material 5‐7

Note
The instructions for disposal of waste material are recommenda-
tions, derived from regulations applied at the place and time
when these operating instructions were issued. You as the oper-
ating company, however, are obliged to inform yourself about
the regulations concerning waste disposal and to proceed
accordingly.
Unless the regulations applicable do no stipulate otherwise, the

waste material is to be disposed of as follows:
O-rings, Sealing rings Residual waste

Lens cleaning paper Residual waste
Swab Residual waste
Cooling water without addi- Sewage system
tives
Cooling water with addi- Disposal in accordance with the applica-
tives ble wastewater disposal regulations for
the region
Tab. 5-2
2.5 Tools and additional equipment
Symbol Designation Dimensions, other data

Slotted screwdriver 3 mm
Hexagon head screwdriver, straight 2 x 1.5 mm for cutting optics, 4 mm
Hexagon head screwdriver, 90° 1.5 mm, 2 mm, 2.5 mm, 4 mm
Open-end wrench 14 mm, 15 mm
Collecting pan for cooling water
Cleaning cloth to wipe up drained water
Blow-out gun for compressed air
5‐8 Material 2019-03 21-01-29-CRen

Symbol Designation Dimensions, other data
Pin-type face spanner cutting optics accessory, necessary
for replacing the protective glass
Triangular scraper For removal of material deposits

(only for lenses with exhauster)
Protective gloves rubber, to be worn when handling

deionized water
Steel brush to remove material deposits on the

crossjet and the shielding gas sup-
plies
Polishing fleece to remove material deposits on the
crossjet and the shielding gas sup-
plies
Optics cleaning kit(see "Optics contains tools and consumables for

cleaning kit", pg. 5‐6) maintenance work on the focusing
optics
TE-01607
Key for optics welding optics accessory, necessary

for replacing the protective glass
Tools and auxiliary tools for maintenance Tab. 5-3
21-01-29-CRen 2019-03 Material 5‐9

3. Laser light cable (LLK)
3.1 Disconnecting the LLK from the

focusing optics
If you need to separate the LLK from the focusing optics, the
same rules as for connecting apply. Avoid anything that poses a
risk of soiling.
Conditions
■ The focusing optics is mounted to the carrier. The LLK is
still connected.
■ The focusing optics can be rotated on the carrier so that the
shaft of the plug receptacle is horizontal or the focusing
optics can be dismounted from the carrier with connected
LLK and then put on a clean surface.

■ Adhesive PVC tape, 19 mm, material no.: 1420313
■ Sealing plug for plug receptacle of the focusing optics
■ Protective cap for LLK plug
Dirt in beam guideway!

NOTICE
LLK or focusing optics might get damaged.
Ø Leave openings on LLK and focusing optics unprotected as
short as possible.
Ø Put the plug receptacle of the focusing optics in horizontal
position.
Ø Do not touch optical surfaces.
1. If there is a protective sleeve, remove it.

2. Disconnect electrical cables and cooling water hoses from
the focusing optics.
5‐10 Laser light cable (LLK) 2019-03 21-01-29-CRen

Dismounting the LLK plug Fig. 5-2
3. Loosen the adhesive tape from the joint (1).
4. Unplug the LLK plug from the plug receptacle of the focus-
ing optics (2) ... (4).
260-57-T
Mounting the sealing plug Fig. 5-3
5. Immediately plug in the sealing plug in the plug receptacle
(1) ... (4) and put the protective cap on the LLK plug.
Fig. 5-4
6. If possible, adhere seal band to the beginning of the adhe-
sive tape on focusing optics and LLK plug.
21-01-29-CRen 2019-03 Laser light cable (LLK) 5‐11

The focusing optics can now be handled separately from the
LLK.
5‐12 Laser light cable (LLK) 2019-03 21-01-29-CRen

4. Welding optics
The lens is covered on the outside by a protective glass. The

protective glass protects the lens against soiling by particles or
material vapors formed during the welding process.
Clean the protective glass if:

■ the welding results are affected negatively.
■ the protective glass is dirty.
Change the protective glass if:

■ dirt particles cannot be removed by cleaning (e.g. burnt-in
particles).
■ there are scratches on the protective glass.
The additional protective glass must be changed if:

■ the additional protective glass is dirty.
■ there are scratches on the additional protective glass.
Hot surfaces can burn your skin!

WARNING
Ø Avoid contact with hot surfaces.
Ø Allow the focusing optics to cool down, before carrying out
maintenance or cleaning work.
Note
Touch neither the protective glass nor the focusing lens with the
fingers.
For cleaning, use methyl alcohol. Other cleaning agents can
damage the O-ring or the coating of the protective glass.
4.1 Cleaning the protective glass in the

lens protection
Condition
shackle padlock.
21-01-29-CRen 2019-03 Welding optics 5‐13

or

■ Lens cleaning paper or swab
■ Methanol
■ Disposable gloves
Note
fingers.
damage the O-ring.
1. Soak the lens cleaning paper or a swab with methyl alcohol.

2. Slowly wipe across the protective glass until it is clean.
or
Ø If the protective glass is so dirty that the impurities can-
not be removed when installed, the protective glass must
be removed for cleaning.
Note
Only one side of the protective glass may be used.
After cleaning the protective glass, never fit it into its holder with
the cleaned side towards the lens. The cleaned surface contains
residual contamination, which will vaporize when the laser oper-
ates and which may lead to damage (contaminants being
burned in) to the lens.
Note
The protective glass will have to be replaced if it contains burnt-
in dirt particles, which cannot be removed by cleaning.
4.2 Changing the protective glass of the

lens protection
Material numbers are shown in the list of wearing parts (see

"Tab. 5-1", pg. 5‐6).
Condition
shackle type connector.
5‐14 Welding optics 2019-03 21-01-29-CRen

or

■ Key for optics
■ New protective glass
■ New O-ring (if required)
■ New lens (if required)
Note
fingers.
0030-35-T
1
1 Lens protection 2 Lens

Removing the lens protection Fig. 5-5
6
7
0030-36-T
3 Retaining ring 6 protective glass holder

4 Protective glass 7 O-ring
5 O-ring
Lens protection, components Fig. 5-6
Removing the protective 1. Screw lens protection (2) off the lens (2) counterclockwise.
glass

2. Cover the focusing lens in a loaded ambience (e.g. in case
of oil mist or strong dust), until you reattach the lens protec-
tion.
3. Unscrew the retaining ring (3) using the optics key.
4. Take the protective glass(4) and O-ring (5) out of the protec-
tive glass holder (6).
5. When the O-ring (7) is damaged, replace it.
6. Soak lens cleaning paper or cotton wool with methyl alcohol
and clean the protective glass holder and the O-ring.
7. Insert O-rings in the protective glass holder. Ensure that the
O-rings fit correctly in the slot.
Inserting new protective 8. Put new protective glass in the protective glass holder.
glass 9. Insert retaining ring and tighten it by using the key for the
optics.
10. Check the focusing lens:
Ø If the focusing lens is soiled, soak lens cleaning paper or
cotton wool with methyl alcohol and slowly wipe across.
or
Ø In case of visible damage, change the lens (see "Chang-
ing a lens without cooling ring", pg. 5‐28)(see "Chang-
ing a lens with a cooling ring", pg. 5‐30).
11. Screw the lens protection clockwise on the lens.
If your focusing optics is provided with a crossjet, change the
protective glass in the same way as for the lens protection
described above.
4.3 Cleaning the protective glass in the

protective glass cassette
Condition
or

■ Lens cleaning paper or cotton wool
■ Methanol

3
1
2
4
ct-00203
1 Protective glass cassette 3 Cassette module 4 Protective glass
2 Catch
Fig. 5-7
1. Press in the catch (2) and pull out the protective glass cas-
sette (1).
Tip
then the protective glass to be cleaned or changed in a
clean environment.
Note
Do not touch the protective glass cassette with the fingers.
Clean the protective glass in a clean environment.
ct-00213
Fig. 5-8

2. Cover the opening of the protective glass cassette in conta-
minated environment (e.g. in case of oil mist or a very dusty
environment), until you reinsert the protective glass cassette.
3. Soak the lens cleaning paper or cotton wool with methyl
alcohol.
5. Push the protective glass cassette into the cassette module
until the ratchet engages.
4.4 Replacing the protective glass of the

protective glass cassette (protective
glass cassette NU (NU=groove ring),
starting from September 2016)
Material numbers are given in the list of wear parts (see "Tab.
5-1", pg. 5‐6).
Condition
or

■ New O-ring 52 x 1.5 flap (if required)
■ New frame seal EPDM-60 for handle (if required)
■ New grooved ring with snap-in nose for flap (if required)
■ Epoxy resin (if required)
■ Methanol
■ New focusing lens (if required)

4
ct-00204
3
1 5
1 Catch 3 Flap lock 5 Frame seal EPDM-60 for handle

2 Grooved ring with snap-in nose 4 O-ring 52 x 1.5 for flap 6 Protective glass
for flap
Fig. 5-9
Removing the protective 1. Press in the ratchet (1) and pull out the protective glass cas-
glass sette.
Tip
then the protective glass to be cleaned or changed in a
clean environment.
3. Turn the lower edge of the protective glass cassette
upwards.
4. Press flap lock (3) downward.
The flap springs open.
5. Take the protective glass (6) out of the protective glass cas-
sette.
and clean the protective glass cassette.
7. Clean the O-ring D52x1.5 of the flap (4) with methanol.
or
Ø If the O-ring is damaged, replace it.
8. Clean the frame seal of the handle (5) with methanol.
or
Ø If the frame seal is damaged: change the frame seal.
Glue in new frame seal, if required, with 8 points of
epoxy resin glue (e. g. Loctite 3422).
9. Clean grooved ring of the flap (2) with methanol.
or
Ø If the grooved ring is damaged: change the grooved ring.
Insert new grooved ring.
10. Make sure that the grooved ring sits correctly in the groove.

Inserting a new protective Note
glass
ct-00213
Fig. 5-10
11. Insert a new protective glass into the protective glass cas-
sette.
12. Close the flap.
13. Check focusing lens:
Ø If the focusing lens is soiled, remove, depending on the
version, crossjet, soak lens cleaning paper or cotton
wool with methyl alcohol and slowly wipe the focusing
lens, until it is clean.
or
Ø In case of visible damage, replace the lens.
4.5 Replacing the protective glass of the

protective glass cassette

"Tab. 5-1", pg. 5‐6).
Condition
or

■ New O-ring D52 x 1.5 flap (if required)
■ New O-ring on handle (if required)

■ New O-ring D50 x 2 flap (if required)
■ Methanol
■ New focusing lens (if required)
ct-00204
3
1 5
1 Catch 3 Flap lock 5 O-ring on handle

2 O-ring 50 x 2 flap 4 O-ring D52 x 1.5 flap 6 Protective glass
Fig. 5-11
Removing the protective 1. Press in the catch (1) and pull out the protective glass cas-
glass sette.
3. Turn the lower edge of the protective glass cassette
upwards.
4. Press flap lock (3) downward.
The flap springs open.
5. Take the protective glass (6) out of the protective glass cas-
sette.
and clean the protective glass cassette.
7. Clean the O-ring D52x1.5 of the flap (4) with methanol.
or
Ø If the O-ring is damaged, replace it.
8. Clean the O-ring of the handle (5) with methanol.
or
Ø If the O-ring is damaged, replace it. Fix new O-ring in
8 points by means of epoxy resin (e. g. Loctite 3422).
9. Clean the O-rings D50x2 of the flap (2) with methanol.
or
Ø If the O-ring is damaged, replace it. Fix new O-ring in 8
points by means of epoxy resin (e. g. Loctite 3422).
10. Ensure that the O-rings fit correctly in the groove.

Inserting new protective Note
glass
ct-00213
Fig. 5-12
11. Put new protective glass in the protective glass cassette.
12. Close the flap.
13. Check the focusing lens:
wool with methyl alcohol and slowly wipe the focusing
lens, until it is clean.
or
Ø In case of visible damage, change the lens.
until the catch engages.
4.6 Changing the additional protective

glass
Material numbers are given in the list of wear parts (see "Wear-
ing parts", pg. 5‐5).
Conditions
or
■ Crossjet and purging gas supply are shut off.
■ The optics were brought into a clean environment.

■ New additional protective glass (same protective glass as in
the used protective glass cassette)

■ Tool for changing the additional protective glass
■ New clamping ring for additional protective glass (if required)
To change the additional protective glass, a special tool is

required.
1
2
ct-00289
4 3
1 Position of the clamping ring 3 Handle to shape the tool

on the tool 4 Movable part to fit the clamp-
2 Position of the additional pro- ing ring
tective glass on the tool
Tool to replace the additional protective glass Fig. 5-13
ct-00290
1 Additional protective glass 3 Tool to replace the additional

2 Clamping ring protective glass
Tool to replace the additional protective glass in the cas- Fig. 5-14
sette shaft
Removing the additional 1. Press in the latch and remove the protective glass cassette.
protective glass 2. Insert the tool for changing the additional protective glass up
to the stop in the cartridge shaft.
3. Press the tool upward into the cartridge shaft so that it has
full contact.
4. Press the tool together at the handle.

5. Move the tool lightly back and forth.
The clamping ring and the additional protective glass will fall
onto the tool.
6. Move the tool downward and release.
7. Carefully pull the tool out of the cartridge shaft, making sure
that the protective glass and clamping ring do not fall off of
the tool.
Tip
TRUMPF recommends not cleaning the additional protective
glass, but always replacing it with a new additional protec-
tive glass. Reinserting an incorrectly cleaned additional pro-
tective glass could damage the focusing lens.
8. Check the clamping ring for the additional protective glass
for damage and replace if required.
9. If the new additional protective glass should not be inserted
immediately afterward, push in the protective glass cassette
until the latch snaps in.
Inserting new additional 3

protective glass
1
ct-00291
1 Clamping ring 3 Position to align the addi-

2 Position of the additional pro- tional protective glass
tective glass on the tool
Tool to replace the additional protective glass Fig. 5-15
10. Place clamping ring (1) on the stepped diameter on the tool.
Note
Only hold the protective glass by its ground outer surface.
11. Place new protective glass on the upper ring of the tool (2).
12. Align the protective glass on the inner edge of the retaining
ring at the very front of the tool (3).
13. If required, press in the latch and pull out the protective
glass cassette.
14. Carefully insert the tool up to the stop in the cartridge shaft.

15. Press the tool together at the handle.
The clamping ring will be deformed into an oval shape and
can be inserted into the mounting device.
16. Press the tool upward into the cartridge shaft so that it has
full contact.
17. Move the tool lightly back and forth.
18. Release the tool and move it downward.
The protective glass and clamping ring remain in the focus-
ing optics.
19. Carefully pull the tool out of the cartridge shaft.
Are the protective glass and clamping ring still lying on
the tool?
The reason for this could be that you did not apply the tool
so it was flush.
Ø Insert the tool with protective glass and clamping ring
into the cartridge shaft again, as described above.
The protective glass is changed.
4.7 Replacing the lens along with the

cassette module
The following instruction describes how to change a lens,

because the focusing lens is damaged or because processing of
a workpiece requires a lens of a different focal length.
"Wearing parts", pg. 5‐5).
Condition
shackle padlock.
or

■ Hexagon screwdriver, 90°, 4 mm
■ New lens

Note
Please note that you have readjust the focal position if you
select a lens of a different focal length (see chapter "Adjustment
work").

CAUTION water!
ing.
ing.

1 Connecting piece, here: cube 7 Screw (4x)
2 O-ring 8 Connection for purging gas
3 Cassette module and MDE nozzle
4 Coaxial MDE nozzle 9 Cooling water connection
5 Crossjet TL 10 Lens
6 Supply air connection 11 Cooling hose (2 x)
Fig. 5-16
Cooling hoses 1. Loosen knurled nuts on two cooling water connections (9).
2. Disconnect two cooling hoses (11) and hang them into the
collecting pan.
3. Wipe up drained cooling water with an absorbent cloth.

Purging gas hose 4. Loosen knurled nut on the connection for purging gas and
MDE nozzle (8)
5. Take off the scavenging gas hose.
Supply air hose at the 6. Loosen knurled nut on the crossjet (5).
crossjet 7. Pull supply air hose off the crossjet.
Removing the lens Note

Touch neither the protective glass nor the focusing lens with
the fingers.
8. Remove four screws (7).
9. Remove the lens (10) with the cassette module (3) from the
connecting piece (1).
10. Carefully cover the focusing lens to protect it from dirt.
11. If a different focusing lens is not attached immediately:
Cover the opening on the connecting piece with adhesive
film, in order to prevent dirt from entering the connecting
piece.
The opening must be sealed dustproof.
Attaching a different lens Note

When attaching the lens, make sure that the focusing lens
does not get soiled by particles.
12. Slip on the lens.
13. Tighten all four screws.
14. If the lens must be cooled: Attach the two cooling hoses to
the cassette module. Tighten the knurled nuts by hand.
15. If required: attach the purging gas hose. Tighten the knurled
nut by hand.
16. If required, insert the supply air hose into the coupling of the
crossjet. Tighten knurled nut.
4.8 Changing a lens without cooling ring

Condition

or

■ Hexagon screwdriver, 90°, 4 mm
■ New lens
Note
work").
0030-37-T
4
1 Extension piece, here: 3 Lens

90° deflection 4 Screw (4x)
2 O-ring
Changing a lens without cooling ring Fig. 5-17

the fingers.
2. Remove the lens (3) from the connecting piece (1).
3. Carefully cover both sides of the lens to protect the focusing
lens and the protective glass from dirt.
piece.

does not get dirty from dirt particles.
5. Insert O-ring (2) into the lens. Ensure that the O-ring fits
correctly in the groove.
6. Put the lens on the connecting piece.
4.9 Changing a lens with a cooling ring

Condition
shackle padlock.
or

■ Hexagon screwdriver4 mm
■ New lens
Note
work").

CAUTION water!
ing.
ing.

7
6
3
0031-19-T
4
1 Connecting piece, here: cube 5 Cooling ring

2 O-ring 6 Knurled nut (2 x)
3 Lens 7 Cooling hose (2 x)
4 Screw (4x)
Changing a lens with a cooling ring Fig. 5-18
Cooling hoses 1. Loosen two knurled nuts (6).

2. Disconnect two cooling hoses (7) and hang them into the
collecting pan.
3. Wipe up drained cooling water with an absorbent cloth.

the fingers.
5. Remove the lens (3) from the connecting piece (1).
6. Carefully cover both sides of the lens to protect the focusing
lens and the protective glass from dirt.
piece.

does not get dirty from dirt particles.
8. Insert O-ring (2) into the lens. Ensure that the O-ring fits
correctly in the groove.
9. Slip on the lens.

11. Connect the two cooling hoses with the freshly attached
lens. Tighten the knurled nuts by hand.
4.10 Cleaning the splash guard
The crossjet is sealed from below by means of a spatter guard.

Molten material splashes are deposited on the spatter guard dur-
ing the welding process. Clean the spatter guard at regular inter-
vals. The cleaning interval depends on the application and the
resultant soiling.
The spatter guard has to be replaced if:

■ dirt particles cannot be removed by cleaning (e.g. burnt-in
particles).
■ it is damaged.
"Tab. 5-1", pg. 5‐6).
Condition
shackle padlock.
or

■ Steel brush
■ Polishing fleece
■ New spatter guard (if required)

1 5
2
3 2
3
4 4
0031-20-T
Crossjet CJ Crossjet TL
1 Crossjet support with protective 4 Splash guard
glass 5 Crossjet support
2 Crossjet
3 Screw (2x)
Fig. 5-19
1. In case of the crossjet CJ, unscrew two screws (3) and

remove the spatter guard (4).
or
Ø In case of the crossjet TL, turn the coaxial MDE nozzle
sidewards and remove the spatter guard (4) evenly pull-
ing it downwards by hand.
2. Remove deposits on the spatter guard with a steel brush
and polishing fleece.
3. If the spatter guard can no longer be cleaned or if it is dam-
aged: Use new spatter guard.
4. In case of the crossjet CJ, attach the spatter guard and
tighten the two screws.
or
Ø In case of the crossjet TL, push the spatter guard
upwards until it locks into place on both sides and posi-
tion the coaxial MDE nozzle at the center under the
crossjet TL
4.11 Cleaning the shielding gas supply
During the welding process, material splashes from the molten

material deposit on the shielding gas supply line. Clean the
shielding gas supply line at regular intervals. The cleaning inter-
val depends on the application and the resultant soiling.

Condition
shackle padlock.
or

■ Steel brush
■ Polishing fleece
■ New shielding gas supply (if required)
1. Remove the shielding gas supply from the connecting piece

(e. g. 90° deflection).
2. Remove deposits on the shielding gas supply line by means
of a steel brush and polishing fleece.
3. If the shielding gas supply line cannot be cleaned anymore
or if it is damaged: Use a new shielding gas supply line.
Note
The tubes of the multiple tube can be shortened and
changed individually (see "Changing the tubes of the multi-
ple tube", pg. 5‐34).
4. Mount the shielding gas supply line.
4.12 Changing the tubes of the multiple

tube
If the tubes of the multiple tube cannot be cleaned any more

(see "Cleaning the shielding gas supply", pg. 5‐33) or if they are
damaged, they can be removed individually and shortened or
replaced.
"Tab. 5-1", pg. 5‐6).
Conditions
shackle padlock.

or
■ The multiple tube has been removed from the focusing
optics.

■ O-rings (if required)
0031-53-T
1 Set screw (4x) 3 Pipe (4x)
2 O-ring (4x)
Fig. 5-20
Note
The tube may only be shortened until the upper margin of
the tube (1)) (see "Fig. 5-21", pg. 5‐36) when mounted
ends with the O-ring (2).
1. Loosen set screw (1)(see "Fig. 5-20", pg. 5‐35).
2. Remove tube (3).
3. When the O-ring is damaged, replace it. Position the O-ring
carefully with tweezers in the groove.
4. Shorten the tube.

1
2
0031-54-T
3
1 Pipe 3 Chamfer
2 O-ring
Fig. 5-21
5. Attach a chamfer to the longest tube of the multiple tube (3).
This has a positive effect on the gas flow.
6. Insert the tube.
Final work 7. Mount the multiple tube and connect the gas supply.

5. Welding lens for lens with exhauster
The lens is protected by means of a protective glass inserted in

the lens protection. A protective glass protects the lens against
soiling by particles or material vapors formed during the welding
process.

■ the welding results are affected negatively.

■ dirt particles cannot be removed by cleaning (e. g. burnt-in
particles).
Since metal particles will deposit in the exhaust air area of the
lens protection, clean the whole lens protection at regular inter-
vals. The cleaning interval depends on the application and the
resultant soiling.
A correct adjustment of the air supply and the exhauster mini-
mizes the soiling of the lens protection. The optimum adjustment
depends on the processing task.
TRUMPF recommends you to start with the following setting, if

you do not yet have experience:
■ Supply air pressure: 1.0 bar.
■ Vacuum of the exhauster: 14 mbar.
Start with these values and step by step grope for an adjust-
ment which leads to a minimum soiling in your case.
Note
The light path to the focusing optics has to be blocked.
fingers.
damage the O-ring.
5.1 Clean or replace safety glass
The hoses for air supply and exhaust air may remain connected.
21-01-29-CRen 2019-03 Welding lens for lens with exhauster 5‐37

Conditions
■ The air supply is switched off. The exhauster may remain
switched on.

■ Slotted screwdriver, 3 mm
■ Methanol
■ protective glass (if required)
Removing the lens 1

protection 3
2
0030-39-T
1 Exhaust air connection 3 Lens
2 Supply air connection 4 Lens protection
Note
the fingers.
1. Turn lens protection (4) until the bayonet locking disen-
gages. Carefully take off the lens protection from the lens.
0030-40-T
Location of the focusing lens (arrow) Fig. 5-23
5‐38 Welding lens for lens with exhauster 2019-03 21-01-29-CRen

tion.
Inspecting the protective Note

glass
The protective glass is kept in place only by means of a
magnetic ring. Make sure that it does not fall out.
3. Hold the lens protection against a light source and inspect
the condition of the protective glass.
− If soiled, remove the protective glass and clean it.
− If damaged, remove the protective glass and change it.
Dismounting the protective

glass
1
0030-41-T
1 Magnetic ring (sectional view) 3 Protective glass
2 O-ring (sectional view)
Lens protection, position of the protective glass Fig. 5-24
4. Carefully lift up magnetic ring (1) using a slotted screwdriver

and take it out of the lens protection.
5. Put the magnetic ring on a clean surface. Ensure that it will
not come into contact with ferruginous particles.
Note
Do not touch the protective glass with the fingers.
6. Take protective glass (3) out of the lens protection.
7. Take O-ring (2) out of the lens protection.
Cleaning the protective 8. Soak the lens cleaning paper or cotton wool with methyl
glass alcohol.

Replacing the protective 10. If the protective glass cannot be cleaned anymore or if it is
glass damaged: Insert a new protective glass when reassembling
the lens protection.
Assembling the lens 11. Soak lens cleaning paper or cotton wool with methyl alcohol
protection and clean the lens protection and the O-ring.
12. Insert O-ring (2) into the lens protection (see "Fig. 5-24",
pg. 5‐39). Ensure that the O-ring is positioned correctly.
13. Insert a cleaned or new protective glass (3) into the lens pro-
tection and center it.
14. Place magnetic ring (1) on the protective glass. Ensure that
no particles or small iron parts adhere to the magnetic ring.
Attaching the lens protection 15. If a protective cover is attached to the focusing lens, remove
it.
Ø If the focusing lens is dirty, soak lens cleaning paper or
cotton wool with methanol and slowly wipe across until it
is clean.
or
ing a lens without cooling ring", pg. 5‐28)(see "Changing
a lens with a cooling ring", pg. 5‐30).
0030-42-T
Attaching the lens protection Fig. 5-25

17. Place lens protection on the lens. Turn lens protection until
the bayonet locking engages.

5.2 Cleaning the whole lens protection
Conditions
■ The air supply is off. The exhauster may remain switched on.

■ Open-end wrench, 15 mm
■ Triangular scraper
■ Lens cleaning paper
■ Methanol
■ Protective glass (if required)
Note
fingers.
Removing the lens 1

protection 3
2
0030-39-T
1 Exhaust air connection 3 Lens

2 Supply air connection 4 Lens protection
1. For disconnecting the air supply hose, unscrew the spigot

nut at the air supply connection and pull out the hose.
2. Disconnect the exhaust air hose.

0030-40-T
3. Turn lens protection (4) until the bayonet locking disen-
gages. Take off the lens protection from the lens.
tion.
Disassembling the lens

protection
2 2
1
3
0030-43-T
1 2 2
3
1 Internal funnel 3 External funnel

2 Screw (4x)
Removing the external funnel Fig. 5-28
5. Unscrew four screws (2).

6. Take off external funnel (3) from the internal funnel (1).
Cleaning the lens protection 7. Remove deposits on the inside of the external funnel with
the triangular scraper.
8. Remove deposits on the outside of the internal funnel with
the triangular scraper.
9. Soak lens cleaning paper or cotton wool with methanol and
clean the external and internal funnel.
10. Check the protective glass and clean or replace it, if neces-
sary (see "Replacing the lens along with the cassette mod-
ule", pg. 5‐25).
Assembling the lens 11. Place external funnel (3) on the internal funnel (1).
protection 12. Fasten the external funnel with four screws (2).

Attaching the lens protection 13. If a protective cover is attached to the focusing lens, remove
it.
0030-42-T
Attaching the lens protection Fig. 5-29
Ø If the focusing lens is dirty, soak lens cleaning paper or
cotton wool with methanol and slowly wipe across until it
is clean.
or
ing a lens without cooling ring", pg. 5‐28)(see "Changing
a lens with a cooling ring", pg. 5‐30).
15. Place lens protection on the lens. Turn lens protection until
the bayonet locking engages.
16. Reconnect the air supply and exhaust air hoses.

6. Compensation lens of the
compensation cassette
6.1 Replacing the compensation lens of

the compensation cassette

"Tab. 5-1", pg. 5‐6).

■ Key for optics
■ Methanol
■ Lens cleaning paper
■ Compensation lens
■ O-rings (if required)
3
2
1 4
ct-00223
1 Catch 3 Compensation lens 4 O-ring on handle
2 Retaining ring
Fig. 5-30
1. Turn the underside of the compensation cassette upwards.

2. Unscrew the retaining ring (2) using the optics key.
3. Take the compensation lens (3) out of the compensation cas-
sette.
and clean the compensation cassette.
5. Clean the O-ring of the handle (4) with methanol.
or
Ø If the O-ring is damaged, replace it. Fix new O-ring in 8
points by means of epoxy resin (e. g. Loctite 3422).
6. Ensure that the O-ring fits correctly in the groove.
5‐44 Compensation lens of the compensation cassette 2019-03 21-01-29-CRen

Note
Do not touch the compensation lens with fingers.
7. Insert the compensation lens into the compensation cassette.
8. Insert retaining ring and tighten it by using the key for the
optics.
wool with methanol and slowly wipe the focusing lens,
until it is clean.
or
Ø In case of visible damage, change the lens.(see "Replac-
ing the lens along with the cassette module", pg. 5‐25)
10. Push the compensation cassette into the cassette module
until the catch engages.
21-01-29-CRen 2019-03 Compensation lens of the compensation cassette 5‐45

7. Line laser
7.1 Replacing the line laser

"Tab. 5-1", pg. 5‐6).
Condition
■ The line laser has been switched off.

■ Protective cover (if required)
Note
After replacement, the line laser has to be adjusted (see chapter
"Adjustment work", section "Adjusting the line laser").
6 3
5
4
SG-03011
1 Line laser 4 Protective cover

2 Clamping block 5 Allen screw (3x)
3 Allen screw 6 Retaining plate
Fig. 5-31
5‐46 Line laser 2019-03 21-01-29-CRen

Removing the laser 1. Pull the plug of the power supply unit of the line laser from
the power supply.
2. Unwind cable of the power supply unit and attach it to the
line laser.
3. Loosen the three Allen screws (5) of the protective cover (4).
4. Remove the protective cover.
5. Hold the line laser (1) and loosen the Allen screw (3).
6. Remove the line laser.
Replacing the protective 7. If the protective cover is damaged: Use a new protective
cover cover when installing the line laser.
Installing the line laser 8. Insert the line laser (1) into the clamping block (2) and hold
it.
9. Tighten the Allen screw (3).
10. Place the protective cover on the line laser.
Note
Ensure correct position of the protective cover. The exit port
for the line laser must be parallel to the supporting plate.
11. Tighten the three Allen screws (5) of the protective cover.
Note
Ensure that the cable of the power supply unit of the line
laser is installed without tensile stress, buckles and torsional
strain.
12. Lay the cable of the power supply unit.
13. Connect the plug of the power supply unit to the power sup-
ply.
Replacement of the line laser is now finished.
21-01-29-CRen 2019-03 Line laser 5‐47

8. Cutting optics
The lens is protected by means of a protective glass inserted in

the cutting nozzle. The protective glass protects the lens against
soiling by particles or material vapors formed during the cutting
process.

■ the cutting result deteriorates.

■ dirt particles cannot be removed by cleaning (e. g. burnt-in
particles).
The nose piece of the cutting optics must be checked at regular
intervals and cleaned or replaced, if necessary. After change of
the nose piece the cutting optics has to be readjusted.
Note
The light path to the focusing optics is blocked.
fingers.
damage the O-ring.
8.1 Clean or replace safety glass

"Tab. 5-1", pg. 5‐6).
Disconnecting the cutting gas hose is not necessary.
Conditions
■ The cutting gas supply is switched off.

■ Pin-type face spanner
■ Methanol
■ Nose piece (if required)
5‐48 Cutting optics 2019-03 21-01-29-CRen

■ New protective glass (if required)
■ Scriber or small drill (if required)
Note
fingers.
Removing the cutting nozzle

1
2 2
0030-44-T
1 Lens 3 Connection for cutting gas
2 Knurled nut supply
4 Cutting nozzle
1. Unscrew the knurled nut (2) and remove the cutting noz-
zle (4).
0030-45-T

tion.
21-01-29-CRen 2019-03 Cutting optics 5‐49

Inspecting the protective
glass
0031-46-T
2
1 Knurled nut 3 Protective glass

2 Nose piece
Inspecting the protective glass Fig. 5-34
3. Unscrew the knurled nut (1) and remove the nose piece (2).
4. Hold the cutting nozzle against a light source and inspect
the condition of the protective glass.
− If soiled, remove the protective glass and clean it.
− If damaged, remove the protective glass and change it.
Dismounting the protective

glass
4
0030-47-T
1 Ring nut 3 Protective glass

2 Plastic ring 4 O-ring
Remove the protective glass from the cutting nozzle Fig. 5-35

5. Unscrew the ring nut (1) using the pin-type face spanner.
6. Take out the plastic ring (2).
7. Take protective glass (3) out of the cutting nozzle.
8. Take O-ring (4) out of the cutting nozzle.
Cleaning the protective 9. Soak the lens cleaning paper or cotton wool with methyl
glass alcohol.
Replacing the protective 11. If the protective glass cannot be cleaned anymore or if it is
glass damaged: Insert a new protective glass when reassembling
the cutting nozzle.
Installing the protective 12. Soak lens cleaning paper or cotton wool with methyl alcohol
glass and clean cutting nozzle, plastic ring and O-ring.
13. Insert O-ring (4) into the cutting nozzle. Ensure that the O-
ring is positioned correctly.
14. Insert cleaned or new protective glass (3) into the cutting
nozzle.
Note
Check correct position of the O-ring. The O-ring can be hit
by the laser beam if it projects in the beam guideway. The
whole cutting optics can thereby be destroyed.
15. Insert the plastic ring (2) into the cutting nozzle.
16. Insert the ring nut (1) and carefully tighten it using the pin-
type face spanner.
Cleaning or changing the

nose piece
1
2
0030-48-T
1 O-ring 3 Knurled nut

2 Nose piece
Detaching the nose piece Fig. 5-36
17. Unscrew the knurled nut (3) and remove the nose piece (2).
18. If the nose piece is clogged: Remove deposits on the inside
of the nose piece using a suitable tool. Clear nozzle using,
for example, a scriber or a small drill.

Note
If the nose piece is worn, the reason for this may be that
your cutting optics was not adjusted properly. In this, case,
check the adjustment of your cutting optics. Readjust the cut-
ting optics, if necessary. Proceed as described in the next
section.
19. If the nose piece is worn on one side or is damaged:
Replace the nose piece (see "Fig. 5-36", pg. 5‐51).
Note
The ID no. of the nose piece is engraved.
20. Ensure that the O-ring fits correctly in the groove of the
nose piece.
21. Insert nose piece in the cutting nozzle and fasten it with the
knurled nut.
Attaching the cutting nozzle
0030-49-T
View into the cutting nozzle, coding slot (arrow) Fig. 5-37
22. If a protective cover is attached to the focusing lens, remove
it.
Note
Ensure that the coding nut (arrow) engages when putting on
the cutting nozzle. Make sure that the cutting nozzle is fixed
before tightening the knurled nut.
23. Attach the cutting nozzle to the focusing optics. Tighten the
knurled nut by hand.

8.2 Adjusting a cutting optics equipped
with observation optics
The adjustment of the cutting optics must be checked and read-

justed, if necessary, in case the nose piece of your cutting
optics is used up or the nose piece has been changed.
By adjusting the cutting optics,

■ the nose piece is centered in x-y direction towards the
focused laser beam.
■ the correct distance from nose piece to workpiece in the Z
direction is set.
Aligning the cross hairs with the beam

center
Condition

■ Anodized aluminum sheet
1. Put an anodized aluminum sheet on the working table.

2. Adjust the working distances between cutting optics and
workpiece.
3. Apply a small weld point (for setting values see chapter
"Adjustment work", section "Adjusting the working distance")
4. View the processing point through an eyepiece or on the
screen.
5. Adjust the cross hairs (see chapter "Adjustment work")
6. Mount nose piece (see "Clean or replace safety glass",
pg. 5‐48).
Adjusting the x-y direction

■ 2 x hexagon head screwdriver, 1.5 mm

0030-50-T
Adjusting screws at the cutting optics (arrows) Fig. 5-38
1. View the processing point through an eyepiece or on the

screen.
Note
Turn two opposite screws simultaneously. Turn out one
adjusting screw as far as you turn in the other one.
2. Adjust the cutting optics in x-y direction until the cross hairs
are exactly in the center of the nozzle hole. Do this by turn-
ing the adjusting screws at the cutting optics (arrows).
This completes the adjustment in the x-y direction is completed.
Adjusting the z direction
For the cutting optics, the adjustment of the focal position can
be done by various means, depending on cutting task and equip-
ment:
■ by means of a thickness gage
■ by defocusing.
■ by shifting the cutting optics or the workpiece

z direction adjustment by means of a
thickness gage
Conditions
■ The defocusing unit is in zero position.
■ The focal distance between the lower edge of the nose
piece and the workpiece is adjusted according to the dimen-
sional drawing.

■ Thickness gauge
1
4
0030-51-T
2
3
1 Wing nut 3 Nose piece

2 Knurled nut 4 Lower part of the cutting noz-
zle
1. Adjust working distance between 0.1 and 1.0 mm, as

requested. Do this by putting an appropriate thickness gage
between nozzle and workpiece surface.
2. Using the knurled nut (2), turn the lower part of the cutting
nozzle (4) until the desired distance between the nose piece
and the workpiece surface is reached.
3. Loosen the wing nut (1).
4. Lock the lower part of the cutting nozzle with the wing nut.

z direction adjustment by defocusing
Conditions
■ The defocusing unit is in zero position (see label).
sional drawing.
Ø Defocus the cutting optics according to the requirements

(see chapter "Adjustment work", section "Defocusing the
focusing optics").
Z direction adjustment by shifting the

optics or the workpiece
Condition
sional drawing.

■ Thickness gauge
1. Shift the optics or the workpiece as requested.

2. Put a thickness gage between nose piece and workpiece to
adjust the clearance between nose piece and workpiece.
3. Loosen the wing nut (1)(see "Fig. 5-39", pg. 5‐55).
4. Using the knurled nut (2), turn the lower part of the cutting
nozzle (4) until the desired distance between the nose piece
and the workpiece surface is reached.
5. Lock the lower part of the cutting nozzle with the wing nut.
8.3 Adjusting a cutting optics without

observation optics
The adjustment of the cutting nozzle must be checked and read-

justed, if necessary in case the nose piece of your cutting optics
is used up or the nose piece has been changed.

By adjusting the cutting optics,
■ the nose piece is centered in x-y direction towards the
focused laser beam.
■ the correct distance from nose piece to workpiece in the Z
direction is set.
Condition for the adjustment of the cutting optics is that the
working distance between cutting optics and workpiece is
adjusted correctly. Normally the focal point is then on the sur-
face of the workpiece.
If your focusing optics does not provide an observation device
such as an eyepiece or camera, you can adjust the cutting
optics by measuring the temperature at the nose piece.
Adjusting the x-y direction

■ 2 x hexagon head screwdriver, 1.5 mm
■ Suitable thermometer
During measurement high power laser light is emitted from

WARNING the focusing optics.
Laser radiation can burn your skin or damage your eyes
irreparably.
Ø Always wear laser safety glasses when the laser shielding
cover is open and the laser is switched on.
Ø If the laser is switched on, do not reach between the focus-
ing optics and power meter (power probe).
Note
For measuring surface temperatures, it is preferred to use a
digital thermometer with appropriate measuring sensor.

1
0030-52-T
2
1 Adjusting screws 2 Location of the sensor

1. Attach the measuring sensor of a temperature measuring
device to the nose piece of the cutting optics (2).
2. Measure the temperature of the nose piece.
3. Turn on the laser device (see operating instructions for your
laser device).
4. Adjust the laser parameters so that a measurable heating
arises at the nose piece. Damage to the nose piece, how-
ever, should be avoided.
Note
If you are not sure, start with the smallest power.
5. Have laser light emerged with the adjusted parameters for a
defined time (e.g. 10 seconds). Watch the temperature indi-
cator. Write down the temperature rise.
Note
Do not turn the adjusting screws (1) too far! A quarter turn
per trial will be enough.
6. Turn two opposite adjusting screws (1) on the cutting optics.
Unscrew one screw only as far as the other one was tight-
ened.
7. Have again laser light emerged with the same parameters
and for the same period as for the previous measurement.
8. Write down the temperature rise, occurring at the nose piece.
If the temperature is higher than for the previous measure-
ment, you have further defocused the cutting optics while
turning the adjusting screws. If the temperature is smaller
you turned into the direction of an optimum adjustment.
9. Repeat the following steps with the pair of adjusting screws
you have chosen first until you reached the smallest temper-
ature rise.

− Turn the adjusting screws.
− Allow laser light to be emitted.
− Measure increase in temperature.
10. Do the same for the other pair of adjusting screws.
The adjustment of the cutting optics in the x-y direction is com-
plete when the increase in temperature is as low as possible
after the emission of laser light.
Adjusting the z direction
Adjustment of the focal position for a cutting optics without

observation optics is the same as for a cutting optics with obser-
vation optics (see "Adjusting a cutting optics equipped with
observation optics", pg. 5‐53).

Chapter 6
Eliminating faults
1 Conduct in case of malfunctions 6‐2

1.1 Step-by-step procedure: 6‐2
1.2 Troubleshooting 6‐2
1.3 Malfunctions, possible causes and measures 6‐4
2 Observing messages 6‐10
3 Informing the service department 6‐11
21-01-29-CRen 2019-03 Eliminating faults 6‐1

1. Conduct in case of malfunctions
During daily work, malfunctions may occur which have to be rec-

tified before the regular operation can be started again.
1.1 Step-by-step procedure:
1. Identify the cause of the fault.

2. Take the recommended measures.
Actions carried out in order to rectify causes of

DANGER malfunctions might involve risks to you, to other persons
or to material property.
If such risks are not avoided, they can lead to death,
serious injuries or considerable damage to property.
Ø Causes for malfunctions may only be remedied by persons
who are sufficiently familiar with the laser device.
Ø Turn off the laser device, if it does not have to be con-
nected for the elimination of the malfunction.
Ø Check the parts that carry dangerous voltage during opera-
tion for absence of voltage before touching them.
Ø Wear the personal protective equipment if required for the
corresponding action (e.g. laser safety glasses, safety
gloves).
Ø Observe the safety instructions of the manual and of other
documents.
3. Inform the service department of TRUMPF if you cannot

eliminate the malfunction yourself. Describe in detail how the
malfunction occurred.
1.2 Troubleshooting
Ø To identify malfunctions, determine:
6‐2 Conduct in case of malfunctions 2019-03 21-01-29-CRen

− Is it a malfunction of the laser device or of the laser light
cable?
In this case, a message is displayed on the screen, con-
taining information on the location of the malfunction and
the steps for eliminating the causes.
Information on how to deal with the messages can be
found in the operating software manual and in the Opera-
tor's manual for your laser device.
− Was the malfunction caused by an external component?
Example: "EMERGENCY STOP circuit is not closed."
In this case, a message is displayed on the screen, con-
taining information on the possible causes.
− Is it a malfunction of the focusing optics?
Possible causes for malfunctions of the focusing optics
are explained in this chapter (see "Malfunctions, possible
causes and measures", pg. 6‐4).
− Is the machining result unsatisfactory?
Possible causes for unsatisfactory machining results are
explained in this chapter (see "Malfunctions, possible
causes and measures", pg. 6‐4).
21-01-29-CRen 2019-03 Conduct in case of malfunctions 6‐3

1.3 Malfunctions, possible causes and
measures
Malfunction Possible cause Measures

Welding result went off Protective glass dirty Clean or replace the protective glass
(see chapter "Maintenance")
To identify dirt on the protective

glass, for example caused by oil mist
that cannot be detected immediately
by visual check, measure the laser
power applied to the workpiece:
■ with the protective glass used and
■ with a new protective glass.
If the values differ, the protective
glass is soiled or damaged.
Crossjet:
■ Check air pressure on the supply
air connection; hoses may not be
bent or squeezed. Check spatter
guard for dirt; clean or replace it,
if necessary (see chapter “Mainte-
nance”)
■ Check the gas quality, use only oil
and water-free compressed air,
check oil and water separator at
regular intervals
Exhauster:
■ Check or adjust the volumetric
flow of supply and exhaust air
(see chapter "Mounting and instal-
lation")
■ Check flow rate and hoses for
buckles or squeezing
■ Check lens protection for soiling,
clean or replace it, if necessary
■ Check the gas quality, use only oil
check oil and water separator at
regular intervals
Protective glass damaged Change the protective glass (see
chapter "Maintenance")
Additional protective glass dirty or Changing the additional protective
damaged glass (see "Maintenance" chapter)
Focusing lens soiled or damaged Clean the focusing lens or change
the lens and determine again the
focal position (see chapter "Mainte-
nance")
Incorrect working distance Adjust working distance (see chapter
“Adjustment work”)
Focal position misadjusted Check or adjust the defocusing (see
chapter “Adjustment work”)

Welding result went off LLK-B not connected correctly Loosen the locking screw on the
plug receptacle; check whether the
keying pin at the optical plug is
engaged correctly in the slot of the
focusing optics, insert plug as far as
possible; tighten the locking screw
(see the Operator's manual of the
laser device)
Dual focus optics misaligned Adjust dual focus optics and fasten
the locking screws (see chapter
"Adjustment work")
Position of optics changed (collision, Readjust the optics to workpiece
vibration, insufficient fastening) (see chapter "Adjustment work")
Position of workpiece changed Adjust position using the viewing
optics or camera (see chapter
“Adjustment work”)
Welding speed changed Adjust the welding speed
Check whether the machine moves
at the set velocity
Laser parameters changed Using a pulsed laser:
■ check pulse power
■ check pulse duration
■ check pulse frequency
■ Power measurement with a clean
protective glass
■ Troubleshooting in the laser
device (see Operator's manual of
the laser device)
When using a CW laser device:
■ check the set power
■ Power measurement with a clean
protective glass
■ Troubleshooting in the laser
device (see Operator's manual of
the laser device)
Objects project into the beam guide- Take objects out of the beam guide-
way (e.g. shielding gas supply, optics way (see chapter “Adjustment work”)
protection, devices)
Focusing lens soiled or damaged Call the TRUMPF customer service
from the inside
Bend radius of LLK insufficient Check the laying of the LLK-B,
observe a bending radius of min.
200 mm
Modifications of workpiece: Check joining device and workpieces
■ Joining geometry (such as joining
gap, chamfer)
Modifications of workpiece: Use uniform material quality
■ Condition of surface (such as coat-
ing type, layer thickness, applica-
tion method)

Welding result went off Modifications of workpiece: Check cleaning method and agent,
clean again if necessary
■ Joining zone soiled
Modifications of workpiece: Change specification of the material
■ Material composition modified
Wire supply: Optimize wire velocity
■ Inconstant or incorrect wire velocity
Wire supply: Adapt device to wire diameter
■ Wire diameter
Wire supply: Adjust wire position
■ Wire position maladjusted
Wire supply: Check wire material
■ Wire material inappropriate or too
old
Water-cooled optics: ■ Check the connections of the cool-
ing water supply
■ Water on protective glass or work-
piece
■ Check the cooling water hose
Water-cooled optics: Tighten connections of the cooling

water supply
■ Connections of the cooling water
supply are leaking
Water-cooled optics: Replace cooling water hose and pro-
tect it against radiation
■ Reflected radiation by workpiece
has caused cooling water hose to
melt
Attenuation and deflection of the Use MDE nozzle
laser light due to the metal damping
effect (plasma torch)
Strong spatter formation Laser power increases too quickly at Program a start and end ramp for
the beginning or decreases too the laser power in the laser program
quickly at the end. (see the TruControl 1000 software
manual, doc. no. 10-06-80-A1-CR).
Welding seam not smooth Effects of shielding gas insufficient Check shielding gas supply:
■ Level of gas bottle;
replace empty gas bottle if neces-
sary
■ Hoses;
they must not be buckled or

squeezed
■ Flow rate;
check nozzles for soiling, clean or

replace them, if necessary
■ Gas quality
■ Gas type

Cutting result deteriorated Effects of shielding gas insufficient Check shielding gas supply:
■ Level of gas bottle;
replace empty gas bottle if neces-
sary
■ Hoses;

squeezed
■ Flow rate;
check nozzles for soiling, clean or

replace them, if necessary
■ Gas quality
■ Gas type
Cutting result deteriorated Nose piece soiled or damaged Clean or replace nose piece and
adjust cutting optics (see chapter
"Maintenance")
Nose piece with wrong diameter used Check ident. no. of the nose piece
and replace nose piece if necessary
Laser beam touches nose piece ■ Check nose piece for soiling,
clean or replace it, if necessary
■ Adjust the cutting nozzle (see
chapter "Maintenance”)
Laser beam not centrally through Adjust the cutting nozzle (see chap-
nose piece ter "Maintenance”)
Focusing lens soiled or damaged Call the TRUMPF customer service
from the inside
200 mm
Cutting result deteriorated Distance of cutting nozzle to work- Adjust the cutting nozzle (see chap-
piece changed ter "Maintenance”)
Focal position misadjusted Check or adjust the defocusing (see
chapter “Adjustment work”)
Machine deviates from contour and Check and adjust:
velocity ■ Machine velocity
■ Path precision
■ Distance between nose piece and
workpiece

Optical system overheated Insufficient cooling water flow or no Check the following:
cooling water flow at all ■ Flow
■ Hoses;
squeezed
200 mm
Protective glass dirty Clean or replace the protective glass
To identify dirt on the protective

glass, for example caused by oil mist
that cannot be detected immediately
by visual check, measure the laser
power applied to the workpiece:
■ with the protective glass used and
■ with a new protective glass.
If the values differ, the protective
glass is soiled or damaged.

Optical system overheated Protective glass dirty Crossjet:
Check pressure at the supply air con-
nection and hoses for buckling or
squeezing
Check spatter guard for soiling, clean
or replace it, if necessary (see chap-
ter “Maintenance”)
Check the gas quality, use only oil
check oil and water separator at reg-
ular intervals
Suction system:
Check or adjust the volumetric flow
of supply and exhaust air (see chap-
ter "Mounting and installation")
Check flow rate and hoses for buck-
les or squeezing
Check lens protection for soiling,
clean or replace it, if necessary (see
chapter "Maintenance")
Check the gas quality, use only oil
check oil and water separator at reg-
ular intervals
Reflection from workpiece Cool optics (retrofitting necessary)
Dirt on optical components (collima- Visual inspection of the optics:
tion, mirror, lens) ■ Loosen and remove the LLK plug
■ Hold the optics against a light
source and inspect its condition
via the plug receptacle
Replace the optical component if
soiled, Call the TRUMPF customer
service
Utilization of the optics higher than Call the TRUMPF customer service
originally planned
Incorrect welding position Eyepiece or camera maladjusted Adjust eyepiece or camera (see chap-
ter “Adjusting work”)
Dual focus optics misaligned Adjust dual focus optics and fasten
the locking screws (see chapter
"Adjustment work")
Monitoring through observation Incorrect protective glass inserted Install a broadband antireflective
optics or camera unsatisfactory coated protective glass (see chapter
"Maintenance”)
Illumination maladjusted Adjust diaphragm lever (see chapter
"Adjustment work")
Power supply interrupted Check power supply, re-establish
power supply if necessary
Monitoring through observation Illumination module luminous inten- Set light intensity
optics or camera unsatisfactory sity changed
Illumination module bulb defective Replace bulb (see operating instruc-
tions illumination module)
Tab. 6-1

2. Observing messages
Depending on the used modules, numerous operating values of

the focusing optics will be continuously monitored. If an operat-
ing value is outside of the permissible range, a message is dis-
played on the screen which contains information about the possi-
ble causes and measures to take to remedy this.
The following figure shows an example.
Message (example) Fig. 6-1
For further information on messages and the necessary actions,

please refer to your laser operator's manual.
6‐10 Observing messages 2019-03 21-01-29-CRen

3. Informing the service department
If a fault occurs and you need assistance in eliminating it,

please contact the TRUMPF service department. The service
address is to be found at the beginning of these operating
instructions, following the front page.
Please tell the service staff as precisely as possible:

■ What happened?
■ What has been displayed on the screen (e.g. message,
message code)?
■ What did you do?
■ Is your laser device provided with the telepresence option?
If yes, indicate the number of the connection.
The service staff will do their best to eliminate the fault as
quickly as possible
Applications Laboratory The Applications Laboratory of TRUMPF will be glad to give

advice on application problems.
21-01-29-CRen 2019-03 Informing the service department 6‐11

6‐12 Informing the service department 2019-03 21-01-29-CRen

Operator's Manual

Uploaded by

Copyright:

Available Formats

Operator's Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operator's Manual

Uploaded by

Copyright:

Available Formats

Operator's manual

Original operator's manual

TRUMPF Laser GmbH

TRUMPF Laser GmbH

© TRUMPF Laser GmbH

What do the operating These operating instructions contain important information on

Examples of work on the laser product:

Documentation for further ■ Operator's manual for the laser device.

21-01-29-CRen 2019-03 Before you proceed ... I

1 For your safety 1‐3

2 Warning instructions 1‐4

5 Safety of the laser product 1‐12

6 Measures of the user 1‐19

21-01-29-CRen 2019-03 Table of contents 0‐1

Assembly and installation 2‐3

1 Integration into a system environment 2‐4

3 Ambient conditions 2‐39

4 Using shielding gas 2‐41

0‐2 Table of contents 2019-03 21-01-29-CRen

1 Models and options 3‐3

21-01-29-CRen 2019-03 Table of contents 0‐3

3 Functional description 3‐59

Chapter 4 Adjustment work

General notes on adjustment work 4‐3

1 Aligning the focusing optics 4‐4

2 Adjusting the focal position 4‐5

0‐4 Table of contents 2019-03 21-01-29-CRen

3 Adjusting the dual focus optics 4‐21

4 Adjusting the observation devices 4‐29

1 General notes 5‐3

21-01-29-CRen 2019-03 Table of contents 0‐5

3 Laser light cable (LLK) 5‐10

4 Welding optics 5‐13

5 Welding lens for lens with exhauster 5‐37

6 Compensation lens of the compensation 5‐44

7 Line laser 5‐46

0‐6 Table of contents 2019-03 21-01-29-CRen

Chapter 6 Eliminating faults

1 Conduct in case of malfunctions 6‐2

2 Observing messages 6‐10

3 Informing the service department 6‐11

21-01-29-CRen 2019-03 Table of contents 0‐7

1 For your safety 1‐3

2 Warning instructions 1‐4

5 Safety of the laser product 1‐12

21-01-29-CRen 2019-03 Safety 1‐1

6 Measures of the user 1‐19

1‐2 Safety 2019-03 21-01-29-CRen

Information on the following factors is indicated:

21-01-29-CRen 2019-03 For your safety 1‐3

A warning instruction is information that:

Eyes and skin may be exposed to laser radiation if the

It is absolutely necessary to observe and follow the warning

1‐4 Warning instructions 2019-03 21-01-29-CRen

Laser product Laser products include devices, systems or components used

TRUMPF products summarized under the term "laser product"

Laser light Laser light is electromagnetic radiation with wavelengths from

Other components of lasers might include: