FDB1500-2500 Instruction Manual

7/25/2019 FDB1500-2500 Instruction Manual

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May 26, 2006, Peddinghaus Corporation YD2313149, Rev 0 Page1

INSTRUCTION MANUAL for FDB1500 & FDB2500 Plate Processing Systems

Operation/ Safety/ System Specifications/ Lubrication/ Mechanical Maintenance/ Hydraulics/

Pneumatics

CHAPTER 1 Introduction

Options Covered In This Manual:

Drill Spindle

Signoscript Part Marker

Plasma Torch

Oxy-Fuel Torch


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Table of Contents

Introduction Chapter 1

Title page Chapter 1 Page 1

Table of Contents Chapter 1 Page 2-5

This Manual Chapter 1 Page 6Peddinghaus Corporation Chapter 1 Page 7

Machine Identification Page Chapter 1 Page 8

Documentation Chapter 1 Page 9

Conventions for Notes, Warnings andCautions

Chapter 1 Page 10

Safety Instructions Chapter 1 Page 11

General Notes on Safety Chapter 1 Page 12

Notes on Safety for Specific

Operational Modes

Normal Operation Chapter 1 Page 13

Maintenance / Adjustment Chapter 1 Page 13

Special Sources of Danger Chapter 1 Page 14

Lockout/ Tagout Chapter 1 Page 14

Machine Description Chapter 2

Introduction Chapter 2 Page 15

Optional features Chapter 2 Page 15

Machine specifications Chapter 2 Page 16-17Major components Chapter 2 Page 18

Major electric motors Chapter 2 Page 19

Hydraulic Equipment

Hydraulic Power Unit Chapter 2 Page 20

Accumulators Chapter 2 Page 20

Hydraulic cylinders Chapter 2 Page 21-22

Pneumatic Equipment

Pneumatics Chapter 2 Page 22-23

Electrical Equipment

Electrical Cabinet Chapter 2 Page 23-26

Misc. Electrical Equipment Chapter 2 Page 27-28

Location of Emergency Stop (E-Stop) Buttons

Chapter 2 Page 29

Main Disconnect Chapter 2 Page 29


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Maintenance Chapter 3


Maintenance Safety Chapter 3 Page 30

Lubrication Schedule Chapter 3 Page 31

List of Recommended Lubricants Chapter 3 Page 31

Specifications for Standard

replacement parts

Metric Fastener Torques Chapter 3 Page 32-33

SAE Hoses Chapter 3 Page 34

ASA Steel Tube Chapter 3 Page 34

Steel Pipe Chapter 3 Page 35

Hydraulic power unit

Description Chapter 3 Page 36

Pressure Adjustments Chapter 3 Page 36

Temperature Chapter 3 Page 36

Recommended Oil Chapter 3 Page 37

Recommended Hydraulic Fluid

SpecificationsChapter 3 Page 37

Hydraulic Oil Level Chapter 3 Page 38

Adding Hydraulic Oil Chapter 3 Page 38

Changing the Hydraulic Power Unit

Oil and/or FiltersAbout oil and filters Chapter 3 Page 39

Hydraulic Power Unit Shutdown

ProcedureChapter 3 Page 39

Changing the Hydraulic Oil Chapter 3 Page 40

Changing Hydraulic Power Unit

FiltersChapter 3 Page 41

Grease Fittings

About Grease Fittings Chapter 3 Page 42

Part exit side right Chapter 3 Page 42-44Part exit side center Chapter 3 Page 44-46

Part exit side left Chapter 3 Page 46

Part entry side Chapter 3 Page 47

Drill Transmission Chapter 3 Page 48


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Drill Coolant

Coolant Emulsion Chapter 3 Page 49

Replenishing Coolant Emulsion Chapter 3 Page 50

Pneumatic System

Lubricators Chapter 3 Page 51

Mist Lubricator Filling Chapter 3 Page 51

Oil delivery drip rate chart Chapter 3 Page 52

Filter Draining & Replacement Chapter 3 Page 53

Electrical System Chapter 3 Page 54

Operation Chapter 4


Daily Startup Chapter 4 Page 55

Shutdown Sequence Chapter 4 Page 56Horizontal clamp Chapter 4 Page 56

Smoke collector air flow adjustment Chapter 4 Page 57

Drilling and drill bits

Drill-Bit Usage Chapter 4 Page 58

Defects on Drill-Bits and Their Most

Frequent CausesChapter 4 Page 59

Drill Coolant System Chapter 4 Page 60

Signoscript marker Operation (if

feature present)

About the Signoscript maker Chapter 4 Page 61

Marker service Chapter 4 Page 61-62

Marker Adjustment Chapter 4 Page 63

Plasma-Torch operation (if feature

present)

About the Plasma-Torch Chapter 4 Page 64

Torch tip adjustment Chapter 4 Page 64

Torch Path Routing Chapter 4 Page 65

Correct Torch-Travel Direction forVarious Cut-Offs

Chapter 4 Page 65-67

Kerf & Cutter CompensationDefinitions & Data

Chapter 4 Page 67-68

Optional Kerf Changes Chapter 4 Page 68-69

Plasma torch Summary Notes Chapter 4 Page 69


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Oxy-Torch Operation (if feature

present)

Oxy-Fuel - General Safety

InformationChapter 4 Page 70

The Work Area Chapter 4 Page 70

Protective Apparel Chapter 4 Page 70

Fire Protection Chapter 4 Page 71

Vision Safety Chapter 4 Page 71

Gas Control Panel Chapter 4 Page 72-76

Oxy-Torch Operating Guidelines

Pre-Operation Chapter 4 Page 77

Oxy-Torch Operation Chapter 4 Page 77

Oxy-Torch Cutting Charts

Cutting Chart Data Introduction

(Mild Steel)Chapter 4 Page 78

Acetylene (one piece tips) Chapter 4 Page 79

Natural Gas and Propane (one piecetips)

Chapter 4 Page 80

Liquid. Air, MAPP gas, andPropylene (one piece tips)

Chapter 4 Page 81

Liquid Air and MAPP gas (two piecetips)

Chapter 4 Page 82

Natural Gas, Propane, Chem-o-lene,Butane, and Flamex Model GPN

(two piece tips)

Chapter 4 Page 83

Propylene, Apachi, B-plus, H.P.G.,

RD, T-9, Ucon96, FG-2: Model GPP

(two piece tips)

Chapter 4 Page 84

Kerf Definition and Size Range Chapter 4 Page 85

Cutting and Piercing Information Chapter 4 Page 85-86

Torch Tip Cleaning and Changing

ProcedureChapter 4 Page 87-88

Painting / Colors Chapter 4 Page 89

Drawings & Bills Chapter 6

Assembly Drawings and Bills Chapter 6 Page 90


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This Manual

It is important that all persons supervising, operating, or servicing your Peddinghaus

Corporation Peddimat machine, read and understand this manual.

This manual deals with the mechanical operation and maintenance of your Peddinghaus

Corporation Peddimat system. Some of the features described may be for optional equipment,which you may not have in your system.

Optional equipment will have its own manual. All pertinent manuals will be provided for the

equipment you are receiving. For information on optional equipment that is available for your

machine, contact your Peddinghaus sales representative.

WARNING:

All persons involved with the supervising, installing, operating, or servicing of your

Peddinghaus corporation Peddimat machine should wear appropriate safety glasses,

safety shoes, hard hats, and protective work gloves.

Always observe all notes on safety, and the pertinent operating and maintenance instructions.

This instruction manual, along with the Peddimat and Control Software Manuals, contain allinformation required for operating and servicing the machine.

The Peddinghaus Service Department is always at your disposal to help solve technicalproblems.


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Peddinghaus Corporation

Peddinghaus products have been marketed throughout the world since1903.

In the years prior to 1977, these Peddinghaus products were manufactured in Germany

exclusively. In 1977 Peddinghaus Corporation, located in Bradley, Illinois, was founded and

became actively involved with the engineering, manufacturing, sales and servicing of machinesand systems for the fabrication of plate and structural steel.

Presently, Peddinghaus Corporation manufactures a wide range of manual, PC controlled, and

CNC products for the world market. Peddinghaus Corporation maintains a complete stock of

replacement parts and service technicians to service their products which are successfully soldthroughout the world market.

Peddinghaus Corporation reserves the right to improve or change product design and

specifications without prior notice. In addition, Peddinghaus Corporation assumes no

responsibility for damages, injuries or accidents caused by improper or other than normal use ofits or any related equipment.

PEDDINGHAUS CORPORATION

300 N. Washington Avenue

Bradley, Illinois 60915

Telephone: (815) 937-3800

Telefax: (815) 937-4003


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Machine Identification

MODEL: _________________________________________________

SERIAL NUMBER: ________________________________________

DATE OF MANUFACTURE: ________________________________

CONTROL TYPE/NUMBER: ________________________________

DRIVE CONFIGURATION: ________________________________

ORIGINAL PURCHASER: _________________________________

Note: If spaces are blank, print this page and enter this data for your files.


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Documentation

The complete set of documentation material for your machine includes:

Instruction Manual

Consisting of:

o

Introduction including Machine Identification Pageo Maintenance Instructions

o Operating Instructions

DrawingsConsisting of:

o Mechanical Assembly Drawings

o Electrical Schematics

o Hydraulic and Pneumatic Schematics

o Foundation and Installation Drawings (General Arrangement)

Control Software Manual

Peddimat Software Manual

Installation instructions

Note:

The Control Software Manual and software may be delivered early or handed out during the

training classes. These manuals should be kept safe and considered part of the overall machinedocumentation.

Note:

The foundation and installation drawings are sent at the time the original order is taken. These

drawings should also be kept safe and considered a part of the overall machine documentation.

Note:

The installation instructions are sent as the machine is shipped. Those instructions should be

kept with and considered part of machine documentation.


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Convention For Notes, Warnings & Cautions

Notes, Warnings and Cautions used in these operating instructions are important notes on safety.

Note: Issues that apply only in some cases appear in italic notes.

Note:

Notes on operation and safety appear in a box and must be strictly observed and carried out by

the operator.

These safety instructions apply to everyone involved in the setup, operation, maintenance, andrepair of the machine and have to be read and strictly observed.

CAUTION:

Caution refers to operating and maintenance instructions that must be strictly followed to

prevent damage and destruction.

WARNING:

Warning refers to operating and maintenance instructions that must be strictly followed to

prevent injury or death to persons.

WARNING:

The machine may be put into operation only if all measures required for accident

prevention have been taken. These measures depend on the structural conditions of therespective installation site. For this reason, we strongly recommend planning the measures

for safeguarding your system with your local professional associations.

Note:

Always keep the operating instructions in reach of the system. Make sure that the machine is

operated only by specially trained operators and in strict observation of the notes on safety and

maintenance instructions contained in this manual.


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Safety Instructions

The machine has been designed and constructed according to state-of-the-art technology and

complies with approved operational safety standards. Still, improper operation of the machinemay endanger the operator, any other persons, or their lives, or may affect the operational

integrity of the machine itself or of other material values.

Proper Use

The term proper use of the machine refers to the machining of steel plate by drilling or cutting.

Operate the machine only when it is in technically sound condition and only for performing

operations it has been designed for. Always observe all pertinent safety, operating, andmaintenance instructions laid down in this instruction manual, and be aware of potential

dangers.

Always have malfunctions that may, in any way, affect the safe operation of the machine taken

care of immediately. The term proper use explicitly includes reading of the operating

instructions and observing the pertinent inspection and maintenance instructions.

Improper Use

If the machine is improperly handled by personnel that have not been trained for its operation,

dangerous situations may arise. For this reason, the machine may be run and operated only by

trained personnel authorized to operate it. The system is exclusively designed for the machiningof steel plate by drilling or cutting. Any use of the system for purposes other than or exceeding

that specified above is considered improper. The manufacturer/supplier cannot be held

responsible for any damage resulting from such use. The risk is taken solely by the operator.

Note:

When idling, the noise level of the machine is at 70 dB(A). Due to various influences such asmaterial transport the noise level at the site of operation may exceed 85 dB(A). In this case,

noise-protection measures for the operator are compulsory.

WARNING:

Remove work pieces from the system only with the operating process stopped. The hazard

zone is safeguarded with the recommended safety gratings and safety circuits.

WARNING:

Never enter the hazard zone while your machine is switched on.

WARNING:

Never walk in between or on the roller transfer modules.


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General Notes on Safety

First, familiarize yourself with the machine.

Always keep the operating instructions in reach of the machine. In addition to the operating

instructions, also keep to and apply general legal rules and other mandatory standards as to

accident prevention and environmental protection.

Staff members engaged in performing work at the machine must have read the operatinginstructions before starting their work, especially the sections on safety. Once they have started

their work, it may be too late. This applies in particular to personnel that perform work at the

machine only irregularly, such as equipping or servicing the machine.

Wear personal protective equipment according to company requirements or local laws! Always

observe the pertinent signs on the machine as to safety and dangers. Always keep the safetysigns on the machine in clearly legible condition.

In the case of machine or operational changes affecting safety, shut down the machineimmediately, secure it against tampering, and report the malfunction to the person or department

responsible. Never carry out any modification or redesign of the machine or fit additional

components that may affect the safety of the machine without permission of the supplier. Thisalso applies to the installation and adjustment of safety devices and safety valves.

Always follow the prescribed intervals of inspection and maintenance according to the operatinginstructions.

Work at or operations with the machine may be carried out by reliable personnel only. Observethe legal minimum age. Use trained and instructed personnel only. Clearly define

responsibilities for operation, equipment, maintenance, and servicing. Make sure that onlypersonnel instructed to do so perform operations at the machine.

Work on the electrical system may be performed by electricians or by persons trained toperform electricians work and under supervision of an electrician only. Work on the electrical

system must be performed in keeping with the applicable rules of electrical codes.

Work on the hydraulic system may be performed by specialized personnel experienced in the

field of hydraulics only.

Spare parts must comply with the technical specifications defined by the manufacturer. This is

always the case with spare parts originally supplied by Peddinghaus Corporation.

Note:

Peddinghaus Corporation cannot be held responsible for any damage due to the use of parts,accessories and/or special equipment that has not been originally supplied by Peddinghaus

Corporation.


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Normal Operation

Operate the machine only if all protective and safety installations (e.g. removable safety

devices, emergency devices) have been installed and are operable.

Check the machine at least once every shift for externally visible damage and irregularities! Any

changes (including changes in operation) must be reported to the person/department responsibleat once. If required, stop the machine immediately and secure it against tampering.

Before switching on the machine, verify that nobody is endangered by the starting of the

machine.

Use the machine in accordance with the operating instructions and its intended functional

purpose only.

Maintenance/ Adjustment

Always follow the recommended schedule and instructions for maintenance operations,inspection procedures, adjustments, and replacement of parts. These operations may be

performed exclusively by expert personnel.

For all operations referring to the operation, productional adaptation, re-equipment, or

adjustment of the machine and its safety installations, as well as to inspection, maintenance, andrepair procedures, observe the machine startup and shutdown procedures described in the

operating instructions as well as the notes on maintenance.

Always safeguard the area of maintenance.

If the system is completely shut down for maintenance or repair work, it must be secured againstunexpected reactivation:

Disconnect the main power connection.

Use lockout/tag out procedures on the power switch!

Remove oil and other protective agents from the system, especially from couplings and screw

connections before starting maintenance or repair work. Never use corrosive detergents!

Always re-tighten screw connections you loosened for maintenance and repair work thoroughly.

Refer to specific assembly drawings for torques.

If safety equipment (guards, covers, e-stops, etc.) need to be removed for maintenance or repair

procedures, then they must be remounted and checked immediately after the work has been

completed.

Ensure that operating and process materials as well as replacement parts are disposed of in away that is not harmful to the environment.


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Special Sources of Danger

Use only original fuses with the prescribed ratings! When malfunctions occur in the electrical

power supply, switch off the system immediately, with the main disconnect located on the mainelectrical enclosure, or at the power source circuit box which your company has installed for

this machine.

The electrical system must be checked periodically. Defects, such as loose connections or

charred cables must be taken care of immediately. Use lock-out/tag-out procedures when

performing this step.

Work on the hydraulic system may be performed by specialized personnel experienced in thefield of hydraulics only. The accumulator is "automatic relieving" and will be relieved when

electrical power is turned off.

Periodically check all tubes and screw connections for leakage and externally visible damage.

Eliminate any defects immediately! Oil that exits under pressure may cause severe injuries!

Lockout/ Tagout

Peddinghaus Corporation recommends the use of lockout/tagout of power sources per ANSI

Z244.1-1982 or any more recent revision or standard thereof, and CFR 1910.147 "The control

of hazardous energy [lockout/tagout]" or any more recent revision or standard thereof. It is the

customer's responsibility to provided their employees with the equipment and training to meetthose standards.

Lockout/tagout of energy sources includes pneumatic energy, hydraulic energy [including storedenergy in accumulators], and electrical energy.


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CHAPTER 2 Machine Description

Introduction

The Peddinghaus FDB1500 & FDB2500 are machines used for drilling, cutting and marking of

flat plate. The drill, torches and marker travel from side to side (Y-axis). The plate is positioned

by a full width roller controlling the feed axis (X-axis). Position can be programmed for anyselected combination of drilling, marking, and cutting. The drive mechanism permits you to

program material to be processed from the leading edge to 10 inches from the trailing edge. This

plate drop off is the result of the physical distance between the drive roll and the tool location.

Optional features

Drill unit with either 3 spindles or 1 spindle.

Burning/Marking options include any combination of three of the following:

200 amp Plasma Cutting System 400 amp Plasma Cutting System

Oxy-Fuel Torch System

Signoscript Marking Tool


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Machine Specifications

Type Units of Measure FDB 1500 FDB 2500

Maximum plate width inches (mm) 60 (1500) 96 (2500)

Minimum plate width inches (mm) 2 (50) 6 (150)

Maximum plate thickness inches (mm) 2 (50) 3 (75)Minimum plate thickness inches (mm) 1/4 (6) 1/4 (6)

Maximum length piece

partfeet (mm) 20 (6100) 20 (6100)

Minimum length piece

partinches (mm) 36 (900) 36 (900)

Minimum plate drop off

(trailing edge)inches (mm) 10 (250) 10 (250)

Passline inches (mm) 40 (1016) 40 (1016)

Work piece weight max. pounds (kg) 8,250 (3,750) 20,125 (9150)Maximum velocity X-axis in/min 600 600

Maximum velocity Y-axis in/min 600 600

Maximum hydraulicpressure

psi 1500 1500

Available voltages

380/415V460/480V

230/240V*

575/600V*

380/415V460/480V

230/240V*

575/600V*

Machine Dimensions

(Height x Width x

Length)

approx. inches

approx. (mm)

113 1/2 x 77 x 221

(2883 x 1956 x 5614)

113 1/2 x 77 x 280

(2883 x 1956 x 7112)

Weight approx. pounds (kg) 22,500 (10,225) 28,500 (12,950)

Number of drillspindles**

------------------ 1 - 3 1 - 3

Maximum drill size inches (mm) 2 (51) 2 (51)

Power per spindle Hp (kW) 15 (11.2) 15 (11.2)

Spindle travel inches (mm) 11-13/16 (300) 11-13/16 (300)

Drill spindle rapidadvance speed

inches/min(mm/min)

240 (6096) 240 (6096)

Variable feeds (per

spindle)

inches/min

(mm/min)1 - 12 (25-300) 1 - 12 (25-300)


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Three spindle drill:

Spindle 1="Med." Speed

Spindle 2="Slow" Speed

Spindle 3="Fast" Speed

PC controlled

RPM (Min.- Max.)

RPM (Min.- Max.)

RPM (Min.- Max.)

75-757

62-623

90-907

75-757

62-623

90-907

Single spindle drill:

Speed

PC controlled

RPM (Min.- Max.) 62-623 62-623

*with additional transformer

** Drill Spindles have #4 Morse Taper


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Major Components

Several sub-systems of the plate processing system are semi-independent in that their position

on the shop floor is flexible and may vary depending on your shop characteristics and/or they

are independent functional units manufactured by others. These sub-systems include: the mainmachine, the hydraulic power unit, a plasma torch unit, entry and/or exit roller transfer, and a

dust collecting system (if supplied).

FDB1500 Exit View

Hydraulic power unit.

Plasma torch unit.

Roller transfer module.

Dust collector unit.


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Major electric motors

Drill motor.

Y-axis servo motor.

X-axis servo motor.

Hydraulic power unit motor.


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Hydraulic equipment


All hydraulic equipment is powered by the Hydraulic power unit.


Accumulators

There are two accumulators in the system.

Dump table accumulator.

System Accumulator


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Hydraulic cylinders

Left upper pinch roll

/material hold down

cylinder.

Right upper pinch roll /material hold

down cylinder.

Each of the three drill units is raised

and lowered by a hydraulic cylinder.

(A separate system provides drill bit

cooling air and oil.)

Tooling (Signoscript marker, Plasma Torch, Oxy-fuel

Torch) is raised and lowered by separate hydrauliccylinders.

The hydraulic cylinder located on the Y-axiscarriage is the "parking cylinder". It allows the

drills to "Short Stroke" (retract just enough to

clear the material) when moving betweenholes.

These two hydraulic cylinders operate the parthold down device.


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Hydraulic cylinders continued

Two hydraulic cylinders on each side operate the dump table.

The upper (larger) cylinder raises and drops the table.

The lower (smaller) cylinder raises the dump table about 1/4 inch at the same time as the part

hold down is lowered, to hold the work for drilling.

Pneumatics

1. Regulator and

gauge

2. Filter

3. Manual

shutoff valve

4. Lubricator*

5. Main oiler

6. Filter (for airknife)

7. Pressureswitch

8. Blow gun (notshown)

*(additional for Signoscript motor)


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Pneumatics continued

The two air valves for the air knife are mounted on the part entry side of the machine.

The drill bit coolant system uses air and oil to

lubricate and cool the drill bits.

Also see Drill Operation.

Electrical Cabinet

Programmable

Logic Controller

(PLC)

Main disconnect


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Electrical Cabinetcontinued

Breaker / Motor contactors

1. Drill motor

2. Dust collector

3. X-axis servo motor

4. Y-axis servo motor

5. Hydraulic Power unit

1. Circuit breaker

2. Hour meter

3. Ground

E-stop relay

DC motor drives

1. X-axis servo

2. Y-axis servo


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Electrical Cabinetcontinued

AC variable speedinverter for drill.

24VDC power supply

110V transformer for110VAC power


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Electrical Cabinetcontinued - exterior of cabinet

Electrical cabinet cooler

Cable with RS232

connector for connectingyour computer with

Pedimat software to the

plate machine.

110VAC outlet for computer power (top

line).

Reset buttons. Resets for DC servo drives(bottom line).

Main Operator

panel.


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Misc. Electrical Equipment

Y-axis limit of travel limit

switch.

Y-axis limitswitches

1. Limit of travel

switch.

2. Y-Axis "Zero"

switch.

.

Transformer for Oxy-

fuel torch igniter.Located on Y-Axis

Carriage.

Y-axis

encoder.


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Misc. Electrical Equipment continued

.

Hydraulic Cylinder Valves

(Left To Right)

1. X-Axis Pinch/Drive Roller

solenoids, pressure adjustmentand gauge.

2. Material Hold Downsolenoids and flow

adjustments.

3. Dump Table Raise

solenoids.

4. Horizontal Clamp solenoids,

pressure adjustment and gauge.

.

Dump table solenoids, pressure

adjustment and gauge.


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Location of Emergency Stop (E-stop) Buttons

.

E-Stop exit side

.

E-Stop entry side

Main Disconnect

.

Main Disconnect


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CHAPTER 3 Machine Maintenance

Introduction

The Peddinghaus FDB1500 or FDB2500 must be checked, cared for, and serviced periodically.

Please observe all pertinent notes and instructions.

Should any questions arise that have not been answered in these operating instructions, please

call the Peddinghaus Service Department. You will always reach a competent contact personunder the telephone number (815) 937-3800.

You can also contact the Service Department by fax under (815)937-4003.

Maintenance Safety

WARNING:

Observe pertinent safety regulations when performing maintenance operations. If themachine is operated by untrained personnel and not in accordance with the operating

instructions, or improperly, dangerous situations may arise. Maintenance work may becarried out by trained operators with expert knowledge only. Always wear your personal

safety equipment (hearing protectors, safety shoes, safety gloves, etc.). Never reach into the

zones of operation and machining while the system is in operation.

Never carry out any maintenance or adjustment procedures while the machine is inoperation.

When carrying out maintenance work, always keep unauthorized persons away from the

machine.

Collect used filters in a special-refuse bin and dispose of them in a way that is notharmful to the environment.

Collect oil in a suitable container and dispose of in a way that is not harmful to the

environment.

WARNING:

When you draw off oil at operating temperature you take the risk of scalding yourself.

Before disconnecting hydraulic pipes and carrying out work on the hydraulic power unit,ensure that the pipes are no longer under pressure. Hydraulic oil exiting under pressure

can cause severe injuries.

Never change the adjustment of the valves.

After having completed all work, check all connections, including screw connections fortightness without the system being under pressure.

Never forget to mount all guards and covers properly after the work has been completed.


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Lubrication Schedule

Please take particular note of the lubrication schedule, and the list of recommended lubricants.

Note:

The service life and operability of your machine depend on whether the lubrication andmaintenance schedules are observed.

Before initial startup of the machine, all lubrication points must be supplied with sufficient

lubricant. A filled grease gun must be considered part of the maintenance kit.


Check level daily.

Change fluid after first 1,000 hours of operation.

Change fluid after 2,500 hours of operation or at least annually.

Grease fittings

Lubricate every 200 hours of operation

Dump table rack and pinion

Remove covers and grease after first 1,000 hours of operation and after each 2,500 hours

of operation.

Drill spindle drive transmission

Check level monthly.

Change fluid annually.

List of Recommended Lubricants

LUBRICANT

Transmission Oil- MOBIL GEAR 629

LITHIUM ROLLER BEARINGGREASE(No Moly-Disulfide Added)

MOLYCOTE BR2 GREASE (Moly-Disulfide Paste Grease)


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SPECIFICATIONS FOR STANDARD REPLACEMENT PARTS

Metric Fastener Torques

Socket head cap screw, class 12.9

General usage Special usageTorque induced

screw stress 32,000 PSI(220 Mpa) 100,000 PSI (690Mpa)

screw

sizepitch tensile

area

(mm2)

dry Lubed or

Loctiteddry Lubed or

Loctited

M4 0.7 8.8 13 in-lb

147 N-cm

10 in-lb

113 N-cm

N/A N/A

M5 0.8 14.2 27 in-lb

305 N-cm

21 in-lb

237 N-cm

N/A N/A

M6 1 20.1 46 in-lb

5.2 N-m

35 in-lb

4.0 N-m

N/A N/A

M8 1.25 36.6 111 in-lb

13 N-m

85 in-lb

9.6 N-m

N/A N/A

M10 1.5 58.0 219 in-lb

25 N-m

167 in-lb

19 N-m

N/A N/A

M12 1.75 84.3 32 ft-lb

43 N-m

24 ft-lb

33 N-m

99 ft-lb

134 N-m

76 ft-lb

103 N-m

M16 2 157 106 N-m 80 N-m 329 N-m 251 N-m

M20 2.5 245 206 N-m 157 N-m 644 N-m 489 N-m

M24 3 353 357 N-m 271 N-m 1113 N-m 846 N-m

M30 3.5 561 705 N-m 536 N-m 2204 N-m 1673 N-m

M36 4 817 1231 N-m 933 N-m 3845 N-m 2914 N-m


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Metric Fastener Torques continued

Hex head cap screw, class 10.9

General usage w/high strength

washersTorque induced

screw stress 20,000 PSI (138 Mpa) 90,000 PSI (620 Mpa)

screw

sizepitch tensile

area

(mm2)

dry Lubed or

Loctiteddry Lubed or

Loctited

M4 0.7 8.8 8 in-lb

90 N-cm

6 in-lb

68 N-cm

N/A N/A

M5 0.8 14.2 17 in-lb

192 N-cm

13 in-lb

147 N-cm

N/A N/A

M6 1 20.1 29 in-lb

3.3 N-m

22 in-lb

2.5 N-m

N/A N/A

M8 1.25 36.6 69 in-lb

7.8 N-m

53 in-lb

6.0 N-m

N/A N/A

M10 1.5 58.0 137 in-lb15 N-m

105 in-lb12 N-m

N/A N/A

M12 1.75 84.3 20 ft-lb27 N-m

15 ft-lb20 N-m

90 ft-lb122 N-m

68 ft-lb92 N-m

M16 2 157 66 N-m 37 ft-lb50 N-m

219 ft-lb297 N-m

166 ft-lb225 N-m

M20 2.5 245 129 N-m 98 N-m 580 N-m 442 N-m

M24 3 353 222 N-m 169 N-m 1003 N-m 763 N-m

M30 3.5 561 441 N-m 335 N-m 1983 N-m 1506 N-m

M36 4 817 769 N-m 583 N-m 3463 N-m 2623 N-m

Notes:

Peddinghaus uses Class 12.9 socket head cap screws (970 MPa Proof Strength) and Class 10.9

hex head cap screws (830 MPa Proof Strength).

General usageis bolting of low carbon hot rolled steel in non-fatigue applications.

Special usage and w / high strength washersis bolting of hardened steels or alloys and / or

fatigue applications. Torque is indicated on assembly drawings. Ideally, screws should betorqued to a preload of 60-90% of the proof strength, but the maximum preload is limited by the

strength of the bolted material.

Cadmium plated screws: multiply the tabulated dry torque values by .80.

Zinc plated screws:multiply the tabulated dry torque values by 1.1.

This table does not apply to shoulder or low head screws.


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SAE Hoses

Hose

I.D.Hose

DescriptionSAE Rating:

Work / Burst

(PSI)

Min. bend

radius

(inches)Type

1/4 SAE 100R2 AT 5,000

20,000

4 301

3/8 SAE 100R2 AT 4,000

16,000

5 301

1/2 SAE 100R2 AT 3,500

16,000

7 301

1/2 SAE 100R12 4,00016,000

7 77C

3/4 SAE 100R2 AT 3,100

12,400

9.5 381

1 SAE 100R2 AT 2,500

10,000

12 381

1 SAE 100R12 AT 4,00016,000

12 77C

1 1/4 SAE 100R12 AT 3,000

12,000

16.5 77C

1 1/2 SAE 100R4 150

600

20 881

2 SAE 100R4 150600

12 881

Steel Tube

Hose

O.D.

(inches)

Wall

Thickness

(inches)

ASA Rating:

Work / Burst

(PSI)

1/4 0.035 3,850

15,400

3/8 0.049 4,30014,400

1/2 0.065 3,580

14,300

3/4 0.109 4,000

16,000

1 0.120 3,300

13,200


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Steel Pipe

ASTM A53 Grade B or A106 Grade B Seamless

Work Burst Pressure PSI

Pipe

Size(inches)

40 80 (XS) 160 XXS

1/8 3,500

20,200

4,800

28,000

--------- ---------

1/4 --------- 4,350

26,400

--------- ---------

3/8 1,70016,200

3,80022,500

--------- ---------

1/2 2,300

15,600

4,100

21,000

7,300

26,700

---------

3/4 --------- 3,50017,600

8,50025,000

---------

1 2,10012,100

3,50015,900

--------- ---------

1 1/4 1,800

10,100

3,000

13,900

4,400

18,100

---------

1 1/2 1,700

9,100

2,800

12,600

--------- 7,200

25,300

2 --------- 2,50011,000

4,60017,500

---------

3 --------- 1,600

7,400

--------- ---------

3 1/2 --------- 2,400

9,500

--------- ---------

4 --------- 2,3009,000

--------- ---------

5 1,300

5,500

2,090

8,100

--------- ---------


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HYDRAULIC POWER UNIT

Description

The Hydraulic Power Unit is a separate piece of machinery in that it includes its own motor,

fluid reservoir and filters. The Hydraulic Power Unit is integral to the plate machine in that thepower, control and hydraulic lines are connected to and controlled by the machine.

Hydraulic power unit.

A separate maintenance manual is included with each power unit. A schematic and bill of

material is placed in that manual.

A serial number and date of manufacturing is stamped on each reservoir top.

Pressure Adjustments

Pressure adjustments on the hydraulic power pack and the hydraulic pump are only to be made

by Peddinghaus customer service engineers or by authorized personnel. Any work of this nature

carried out by unauthorized persons will mean that the machine warranty will terminateimmediately.

Control Spring, 2 to 125 PSI, Parker #P78482

Temperature

The minimum starting temperature of the hydraulic oil is between 54 and 57 degrees (12 and 14

degrees Celsius). The standard operating temperature is approximately 120 Degrees (50 degreesCelsius). When temperatures are low the system must be allowed to warm up for 15-30 minutes

before starting operation. This will guarantee proper functioning.


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Recommended Oil

Trouble-free operation, operational safety, and the service life of the entire hydraulic system

depend on the careful selection of the hydraulic oils.

We recommend hydraulic oils that contain active ingredients for improving the stick-slip

phenomenon, avoid disturbing depositions and cavitations, and prevent undesirable reactions ofpenetrated water, in addition to additives providing improved anti-corrosion protection and

aging resistance plus reduced wear.

Note:

The hydraulic oils listed below have proven appropriate for numerous Peddinghaus systems. Wetherefore recommend the use of these oils.

Recommended Hydraulic Fluid Specifications

Premium quality hydraulic oil with a viscosity range between 150-250 SSU (30-50 CST.) at 100

degrees F (38 degrees C). Normal operating viscosity range between 80-1000 SSU (17-180CST.). Maximum start-up viscosity is 4000 SSU (1000 CST.). In addition, the hydraulic oil

should have maximum anti-wear properties, including rust and oxidation treatment.

Under normal operating conditions, temperature rise, and average ambient humidity, operational

life is about 2000 hours. If the neutralization number (total acid number) reaches or exceeds a

value of 2.0, the oil has become corrosive and should be changed regardless of running time.

MANUFACTURER

OILS

Mobil DTE #24

DURO AW Oil 32


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Hydraulic Oil Level

Check the hydraulic oil level before placing the machine into operation. This can be read at the

sight glass on the side of the power unit.

CAUTION:

The hydraulic oil level must not drop below the minimum observable fluid level of the sight

glass.

Oil level sight glass

(and thermometer).

Adding Hydraulic Oil

WARNING:

The Hydraulic Power unit must NOT be in operation when adding hydraulic oil .

1. Shut down operations and turn off thepower at the main power disconnect on

the electrical cabinet.

Use Lockout/tagout procedures.

2. Screw off the tank breather cap.

3. Fill with hydraulic oil using a funnel until

oil level is at full in the sight glass.

4. Screw the tank breather cap back on.


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About Oil and Filters

The Hydraulic Power Unit has both a high-pressure output filter and a return filter. The

replacement filter numbers are found on the filter canisters. The filter has a clogged filterindicator that will rise when the filter is not clean.

Prior to changing the hydraulic oil, the machine must be shut off and any accumulators must berelieved. FAILURE TO DO SO CAN CAUSE SERIOUS INJURY OR DEATH.

The first hydraulic oil change must be done after 1000 working hours (see hour meter in switch

cabinet). Future oil changes must be carried out after 2500 hours and no later than one year. The

reservoir holds 30 gallons (114 liters) of oil.

Install new filters after 1000 hours of operation and replace thereafter when a dirty filter

indicator is observed on the power unit.

The suction strainer should be cleaned at each oil change.

Hydraulic Power Unit Shutdown Procedure

The Hydraulic Power Unit must be shutdown and pressure in accumulators must be relieved

before changing hydraulic oil, changing hydraulic filters, or maintenance work on hydraulic

components.

1.Shut down operations and turn off the

power at the main power disconnect onthe electrical cabinet. Use Lockout /tagout procedures.

2. Check that the pressure gauge

reads zero (0) pressure.


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Changing the Hydraulic Oil

Note:

Check the operating hours counter regularly. The operating hours counter is located in the main

electrical cabinet.

1. Perform the Hydraulic Power Unit Shutdown

Procedure.

2. Remove the tank breather cap and the strainer

beneath the cap.

3. Draw off old hydraulic oil using a barrel

pump and dispose of it in a way that is notharmful to the environment.

4. Open the clean out access panels on bothsides of the tank.

5. Clean the tank.

6. Clean the oil strainers inside the tank.

7. Remove and replace the high pressure filter.

8. Remove and replace the return filter.

9. Replace the access panels.

10. Refill the tank.


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Changing the Hydraulic Power Unit Filters

1. Perform the Hydraulic Power Unit ShutdownProcedure.

2. Check that the pressure gauge reads zero (0)pressure.

3. Remove and replace the high-pressure filter

(3a.) and / or the return filter (3b).


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GREASE FITTINGS

About Grease Fittings

Except where otherwise specified, grease all fittings with pure lithium roller bearing grease (no

Moly-Disulfide or Graphite additives) every 200 hours with a grease gun.

WARNING

Turn off all power and follow lockout/tagout procedures before beginning anymaintenance procedure.

WARNING

Any guards or covers which must be removed for servicing must be completely re-installed

prior to machine start up.

Part exit side (non-datum)


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5.

Part exit side right (non-datum)

6.

Part exit side right (non-datum)


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8.


9.

Lead Screw

10.

Pure lithium

grease


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Y-Axis Rails

11-16 There are six linear rail bearings on the Y-axis carriage, (3) top rail, (3) bottom rail. Each

has a grease fitting.

Dump Table Cam Slots

Remove the covers on both ends of the dump table and grease the dump table gear racks, cam

slots and cylinder guides every six months.

Brush on MOLYCOTE BR2 grease.

Scrap Cart

Grease the scrap cart wheels (not shown).


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Datum Pushers

Grease the datum pushers on the entry conveyor.

Entry conveyor. Datum pusher.

Part exit side (datum)

Part exit side (datum)


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Lead Screw

10.

Datum Rollers (Part entry side)

Most of the part entry rollers have grease fittings. Those without a fitting do not requirelubrication.

Horizontal Clamp (Part entry side)

The grease fittings for the horizontal clamp rail is under the clamp.


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Spindle Feed Cylinders

Depending on the age and model of your machine there may also be grease fittings for the

Spindle Pusher Bearings. Make sure that all spindles are in the fully retracted position. Remove thepipe plug located right next to the Full Retract Prox. Switch on each drill spindle feed assembly to access

the grease fitting. Grease the Pusher Bearing every 1000 hours with a Lithium Sub-Base Grease

(Litholine Complex EP2). IMPORTANT:Make sure to replace the pipe plug to keep contaminates out

of the gearbox.

Drill Transmission

The drill transmission is filled with MOBIL GEAR 629 transmission oil.

Drill transmission oil level sight gauge.

Drill transmission oil fill cap.

The first oil change should occur after 500 operating hours (check at operating hours counter inthe main electrical cabinet), thereafter annually.

To change the oil, remove the drain plug (15/16 inch British Standard Parallel pipe thread) witha hex head wrench. Refill to the center of the sight gauge (approximately 1 1/2 gallons).


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DRILL COOLANT

The Peddinghaus drill is equipped with an air-cooling system for the drill bits. A coolant

emulsion is added to the cooling air.

Coolant Emulsion

We recommend using Tri Chem "Klear Kut" soluble cutting oil. This product mixes well with

any water hardness and is well suited for machining constructional steel.

When the aforementioned product is not available, we also recommend using "MOBILMET 100

SERIES" soluble cutting oil according to the following chart:

Water HardnessMOBILMET 100

SERIES #

Under 500ppm S-122

500ppm or higher S-126

MOBILMET 100 SERIES coolant is primarily used for machining ferrous materials. It is wellsuited for machining constructional steel since changing of color and staining may occur with

certain alloys. It is recommended to test the coolant on the material before using it.

The concentration of the operating emulsion depends primarily on the type of machiningoperation, the power required for it, and the material to be machined. For materials that are

difficult to machine, concentrations of 10:1 (10 parts water to 1 part cutting oil) have proved

suitable. In favor of good corrosion resistance properties, the concentration should be at least

30:1.

In order to guarantee proper mixing of the oil, always stir the coolant into clean water; never

proceed the other way around! If large amounts of emulsion are to be prepared, we recommend

the use of mixing devices.

WARNING: Observe the safety instructions. Wear gloves when carrying out work thatinvolves coolant concentrate. If it gets onto your skin, rinse affected part with water. If it

gets into your eyes, rinse thoroughly with water and seek medical care.


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Replenishing Coolant Emulsion

The coolant reservoir is mounted on the

outside of the electrical cabinet.

The coolant reservoir has a capacity of 4 gallons (15 liters) of emulsion.

To fill the reservoir:

1. Turn the locking lid and remove from tank.

2. Fill the reservoir with coolant emulsion.

3. Replace the lid.


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PNEUMATICS

Lubricators

1. Main lubricator.

2. Additional lubricator for Signoscript

motor.

Parker 18L series mist lubricators are supplied with the plate machines, part number 18L64Bwith manual drain and sight gauge.

Mist Lubricator Filling

Note: Maintenance for a Parker 18L series lubricator follows. See Lubricator manufacturer's

instructions for updates and for other lubricator models.

Inlet pressure must be eliminated before fill plug is removed. SHUT OFF AIR SUPPLY anddepressurize the unit by turning the self-venting regulator to zero pressure. Fill to fill line on the

bowl with oil of 100 to 200 SSU viscosity at 100 degrees F and an aniline point greater than 200

degrees F - same as SAE No. 10(petroleum based hydraulic oils or spindle oils are goodexamples). DO NOT USE OILS WITH ADHESIVES OR TACKY ADDITIVES.

COMPOUNDED OILS CONTAINING SOLVENTS, GRAPHITE, SOAPS OR

DETERGENTS (automotive oils generally contain detergents) ARE NOT RECOMMENDED.

Replace the fill plug and seat firmly (hand tight) - excessive torque is not necessary. The

lubricator is now ready for setting. Re-pressurize the lubricator.

OIL DELIVERY ADJUSTMENT - adjust oil delivery; turn the metering screw in the

top of the lubricator.

LESS OIL - Clockwise

MORE OIL - Counterclockwise

By counting the number of drops per minute in the sight dome, you can adjust your

requirements. Approximately 3% of the drops seen in the sight dome go downstream; adjustdrip rate accordingly. Consult the oil delivery conversion chart on the next page.

25 drops per minute equals one ounce (.03 liters) per hour -volume of oil passing through sight

dome.


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Note:

This is a constant density type lubricator which delivers a constant ratio of oil to air flow.Therefore, if air flow increases or decreases, oil delivery will be adjusted proportionately.

ONLY IF A DIFFERENT RATIO IS DESIRED SHOULD YOUR METERING SCREWSETTING BE CHANGED AFTER YOUR INITIAL SETTING.

Oil Delivery Drip Rate Chart

Your FDB1500 system has an intermittent pneumatic usage. Because of this, the lubricator is set

for a steady dripping of oil. Oil is used only on demand of air, so the oil reservoir should be

checked on a weekly basis.


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Filter Draining

Both free moisture and solids are removed automatically by the filter. There are no moving

parts.

Manual drain filters must be drained regularly before the separated moisture and oil reaches the

bottom of the lower baffle. Automatic drain models will collect and dump liquids automatically.

Note

Collect drained contaminated liquid and dispose of in an environmentally safe manner

The filter element should be removed and replaced when a working pressure of 75 psi (5 bar)

can no longer be set with the regulator.

Filter Replacement

To remove the filter element: SHUT OFF AIR SUPPLY and depressurize the unit by turning theself-venting regulator to 0 (zero) pressure.

1. Unscrew threaded bowl.

2. Unscrew lower baffle and remove filter element and gaskets (2).

3. Clean all internal parts and bowl before reassembling. See to clean

polycarbonate bowls below.

4. Install new element and gaskets (2).

5. Attach lower baffle and tighten firmly.

6. Replace bowl seal; lubricate seal to assist in retaining it in position. Use onlymineral base oils or grease. Do NOT use synthetic oils such as esters and do

NOT use silicones.

7. Screw bowl into body.

TO CLEAN POLYCARBONATE BOWLS USE MILD SOAP AND WATER ONLY! DO

NOT USE cleaning agents such as acetone, benzene, carbon tetrachloride, gasoline, toluene,

etc., which are damaging to this plastic.

Bowl guards are recommended for added protection of polycarbonate bowls where chemical

attack may occasionally occur.


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55/90


CHAPTER 4 Machine Operation

Introduction

Staff members engaged in performing work at the system must have read the operating

instructions when starting their work at the machine, especially the sections on safety. Once

they have started their work, it may be too late. This applies in particular to personnel thatperform work at the machine irregularly, such as equipping or servicing the system.

WARNING

Observe the pertinent safety regulations and the general notes on safety when performingoperations. If the machine is operated by untrained personnel and not in accordance with

the operating instructions, or improperly, dangerous situations may arise. Always wear

your personal safety equipment (hearing protectors, safety shoes, safety gloves, etc.).Never reach into the zones of operation and machining while the system is in operation.

WARNING

The system may be put into operation only when adequate measures required for accident

prevention have been taken i.e. (safety covers, electrical safeguarded gates, etc.).

Daily Startup

The following steps are recommended when starting machine:

1. Check air oiler levels. (Fill if needed)

2. Check air filter/separator. (Empty if required)

3. Check hydraulic power unit oil level.

4. Clean area of drill chips.

5. Check the cleanliness of all the linear ways. Wipe off and lubricate with

Teflon or silicone spray.

6. Check the cleanliness of all exposed cylinder rods, including the horizontal

clamp, and both Y-axis guides. Also check the drill spindles, wipe off and

lubricate with Teflon or silicone spray.

7. Check the sharpness of all drill bits. Resharpen or replace as needed.

8. Turn on main power.

9. Press the "START" button on the Control Console.


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10. When the system is ready, the "E-Stop Warning" may be on the display. If so,be sure all E-Stop switches are open and press the "E-Stop Reset" button to clear

the machine for operation.

Shutdown

The following steps should be executed in sequence when shutting down:

1. Press the "EXIT" button in the software. Answer "YES" to the "Shutdown theentire system?" prompt. Wait for the "Safe to Shut Off Computer" message to

display.

2. Press the "OFF" button on the Control Console to shut off the power to the

machine.

Tool Changes

The software includes a provision for changing the drill-bits on the machine. Please refer to thesoftware manual for the location of the "Tool Change Button" in the program menus. This

button will move the Y-axis to a position that is comfortable for changing the drill-bits.

Use a drill drift to remove the bit or extension from the spindle. If an extension is used, move a

safe work area before removing the bit from the extension.

Insert the extension and/or the drill-bit into the drill spindle and tap lightly using a soft face

hammer. Always double check to be sure the drill-bits and/or extensions are secured correctlyinto the drill spindle.

The drill feed rates are automatically adjusted for every single drill spindle via the P.C. Controland require no manual adjustment

Horizontal Clamp

The horizontal clamp presses the plate against the datum line of the machine. During themachining operation, the work piece is held in position by the X-Axis rollers.

The horizontal clamping device pressure is set by the control between 102-1500 psi (7-103 Bar)


57/90


Smoke Collector Airflow Adjustment (for those machine with a Peddinghaus supplied dust

collector)

Smoke collector for plasma machines air flow adjustment:

The damper adjustment is made by the following technique:

Close the damper almost completely (90%). Burn metal and observe the smoke rising near the

Plasma torch. Adjust the smoke collector's damper tojust capturethe smoke. The damper mustbe securely locked in place after adjusting. Use a tool to assist locking the damper to prevent

loosening from vibration.

1. Variations in smoke collector damper designs might require different damper

adjustments.

2. Do not adjust the damper based on percentage of "open" or" closed", as this is

not a true measure of the actual airflow. 30%closed might only be 5% reduction

of airflow.

3. Changes in duct length and construction may cause each machine installationto have a unique damper setting.

4. As filters are used, "seasoned", the amount of damper will change. New filterswill require a more closed damper. Changing from used, "seasoned", to new

filters will require an evaluation of whether the damper airflow needs to be re-adjusted.

Note

Excessive airflow may cause hot sparks to enter the filter media, or cause particles to becomeimbedded into the filter media. Imbedded particles will prevent filter "self cleaning" during the

purging process.


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Drill Bit Usage

Cooling duct drill-bits are used for extremely high cutting performance. The coolant emulsion is

forced through the cooling ducts under pressure. This process cools the drill bit and enhanceschip removal. Cooling duct drill bits have high operating speeds and long service life, which

makes them very economical.

For drilling without coolant, use standard HSS (High Speed Steel) drill-bits.

Changing drill bits

The software includes a provision for changing the drill-bits on the machine. Please refer to thesoftware manual for the location of the "Tool Change Button" in the program menus. This

button will move the Y-axis to a position that is comfortable for changing the drill-bits.

Use a drill drift to remove the bit or extension from the spindle. If an extension is used, move a

safe work area before removing the bit from the extension.

Insert the extension and/or the drill-bit into the drill spindle and tap lightly using a soft face

hammer. Always double check to be sure the drill-bits and/or extensions are secured correctlyinto the drill spindle.

The drill feed rates are automatically adjusted for every single drill spindle via the P.C. Controland require no manual adjustment.


59/90


Defects on Drill-Bits and their Most Frequent Causes

Defect causing outer edges to break off

Excessive cutting speed.

Hardened spots in the material.

Cutting flutes clogged with chips.

Cutting edges chip

Excessive feed.

Excessive back relief angle on the cutting edge.

Tears in the cutting edgesStress cracking due to overheating or too rapidcooling during regrinding or drilling.

Drill swings out of direction

Drill-bit ground incorrectly.

Excessive feed.

Drill-bit is blunt.

Cutting flutes clogged with chips.

Drill-bit breaksIncorrect fitting between tapered shaft and chuckdue to dirt or chips.

Drill-bit is split right through the centerRelief angle too small.

Excessive feed.

Drill-bit does not catch

Drill-bit is blunt.

Relief angle too small.

Core too strong.

Bored hole has a rough surface Drill-bit is incorrectly ground.

Bore is too largeCutting edge angles or cutting edge lengths are not

identical, or both.

Chip form changes during the drilling

operation

Drill-bit is becoming blunt or the cutting edges

have chipped.

Large chip from one cutting flute, small

chip from the other cutting flute

Drill-bit incorrectly ground, one cutting edge is

doing all the work.


60/90


Drill Coolant System

The Drill coolant emulsion tank is mounted

on the main electrical cabinet.

The emulsion is pumped by an air pump.

1. Air supply to

power pump.

2. Air pump.

3. Emulsionflowadjustment.

4. Emulsionreturn to tank.

5. Emulsion todrill bits.

6. Emulsion

from tank.

The emulsion is

combined with

coolant air.

7. Emulsion from

air pump.

8. Air supply.

9. Air adjustment

valve.

10. Coolant air /

emulsion to drillbits.


61/90


SIGNOSCRIPT MARKER

About the Signoscript Marker

The Plate Machine is optionally shipped with a Signoscript Marker. The Peddinghaus

Signoscript Marker system uses a pneumatic motor to drive a carbide insert cutter. Control ofthe X and Y axis using Peddimat software lets you mark or scribe your parts as needed.

Shown here on the far left is the Signoscript

Marker - next to a plasma torch and oxy-

fuel torch in this optional toolconfiguration.

Marker Service

The cutter and its holders can be accessed by removing the Marker's cup. This is done byreleasing the two clamps that hold it onto the knurled adjustment nut.

Marker with marker cup

removed.

The Marker's pneumatic motor is held in place with a nut and ferrule (2). By loosening the nutwith a spanner wrench (supplied), the motor can be removed.


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Air motor with cutter bit.

The cutter's tool holder is held in the motor by a collet (3). Removing it requires a 1-inch and

5/8 inch thin head wrench (supplied).

Removing the insert cutter from the tool holder requires an insert cutter wrench along with a

5mm Allen wrench (both supplied).

Insert tool Carbide insert cutter


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Marker Adjustment

Initial Cutter adjustment

Initially, set the knurled adjuster nut so that there is about 1/4inch adjustment above the adjuster

nut as shown below.

Then, with the carbide cutter firmly tightened into the cutter's tool holder, slide the tool holder

into the pneumatic motor's collet until there is 7 inches from the bottom of the cutter to thebottom of the adjuster nut as shown. Tighten the collet. This will set the cutter to zero cutting

depth.

Fine Adjustment

The depth of the cut for the marker is set by turning the knurled adjuster (1). One full turncorresponds to 1/16 inch in cutter depth. Each of the four lines scribed in the top of the adjuster

nut adjusts the cutter depth by 1/64 inch. Turning the adjuster nut to the right increases thecutter depth while turning to the left decreases it.

Character Width

With the 90 deg carbide insert cutter installed in the marker (standard with marker option) an

incremental increase in cutter depth will result in an increase of two times that change in

character width.


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PLASMA TORCH

About the Plasma Torch

The Plate Machine is optionally shipped with a Hypertherm Plasma Torch for cutting. The

principle of Plasma-Arc Cutting uses a high velocity jet of hot ionized gas to cut the material. In

order to produce the best possible cuts (least bevel and correct sizing) during Plasma-Arccutting the guidelines on the following pages should be used.

Plasma torch shown as center tool in

optional configuration includingSignoscript marker, Plasma torch and Oxy-

fuel torch.

Torch Tip Adjustment

Torch tip standoff height adjustments are made in the software, see the torch manual for

requirements.

The only mechanical setting is the torch tip is set so it is1/32 inch above the bottom level of the

plasma torch cup. To make this setting move the tooling to tool change position, turn off andlock out power, and be sure the tooling has been allowed to cool. Open the clips (1), and remove

the plasma torch cup. Loosen the nut (2) so the plasma torch height can be adjusted but retains

its position. Replace the plasma torch cup to check the height. When correct, remove the plasma

torch cup and tighten the nut (2). Replace the plasma torch cup.


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Torch Path Routing

The cut produced by a Plasma Torch has a "good side" (approx. 2 to4 degree bevel*) and a

"bevel side" (approx. 7 to 9 degree bevel*).The placement of these sides in relationship to thetorch travel is dependent on the "Swirl Ring" direction (clockwise is standard). All"

Peddinghaus" equipment is supplied with the standard "Clockwise Swirl Ring".

*Depending on the plasma torch model used.

What this will produce is the "Good Side" or "Square side" of the kerf (see page 17 for fullertreatment of kerf) to the right of the torch when viewed from behind. This data must be taken

into consideration when programming parts to be run on an "FDB" machine in order to achieve

the best finished parts possible.

Correct Torch-Travel Direction For Various Cut-Offs

Straight Cut-Off Or Single Trim Cut:"Good" side will be to the right side of torch-travel (or

part trailing edge) when cutoff is performed from the datum side to non-datum side. See leftillustration below.

If leading edge is desired to be "good" side, then cut off must be performed from non-datum

side to datum side. See illustration right illustration above.


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Making A Double Trim Cut: A double trim cut is a cutoff made with the torch traveling fromthe datum side to the non-datum side, followed by a cutoff from the non-datum side to the

datum side. Since the "good" side of the kerf is to the right of the direction of torch-travel, this

results in both pieces having the "good" edges, one being the "trailing edge" of the completed

part and the other being the "leading" edge of the part in process. Peddinghaus Engineeringspecifies the width of a double trim cut to be 1/2"(13mm) for material under 3/4" (19mm) thick,

and 3/4" (19mm) for material over 3/4" (19mm) thick, up to 1 1/4" (32mm) thick maximum. Seeillustration below.

Cutting A Hole With Nearly Square Sides: Cut must be made with the torch traveling counter

clockwise. In this case, the hole will have the "good" side edge. See illustration below.


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Cutting A Circular Plate (Disk) with Nearly Square Sides: Cut must be made with the torch

traveling clockwise. In this case, the disk will have the "good" side edge. See illustration below.

Correct torch travel directions for various cut-offs: Summary illustration below.

Plasma Torch - Kerf & Cutter Compensation Definitions &Data

The term Kerf refers to the gap that is removed as molten metal during the cuttingprocess. This gap is approx. 1/8" and should be verified by the operator when the

material thickness changes and then entered into "Peddimat" as the "Saw or Shear Kerf"

in the "Machine Offsets" section of software status.

The term "comp." refers to "cutter radius compensation" performed by the Fagor CNC.This compensation shifts the actual path of the torch left or right of the theoretical torch

path. The shift amount is half of the Kerf dimension entered in Peddimat. (See

Illustration below). IT IS IMPORTANT THAT THE KERF DIMENSION ENTEREDIS ACCURATE.


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With cutter compensation disabled, custom burns produced by the machine will be

undersized or oversized by half the torch Kerf, depending upon the direction of torch

travel. If cutter comp. is set to the correct side of the torch, (left for standard swirl ring) the

actual torch path would be offset into the scrap portion of the material. This would cause

custom burns to be correct.

If cutter comp. is set to the wrong side of the torch, (right instead of left for example) the

actual torch path would be offset into the finished part instead of the scrap portion of the

material. This would cause custom burns to be under or oversize by the full Kerf value.

Optional Kerf Changes

To obtain optimum edge-cut quality and very accurately sized cut parts determine optimum Kerf

parameters by making successive cut/Kerf checks, and recording this Kerf value. Change thedefault kerf setting in "Peddimat" to this newly determined value.

The Kerf created by plasma burning is a function of many variables, including the feed

rate, material thickness, torch to work distance, gas-pressure settings, amperage setting,and the condition of the consumables.

The feed rate, pressure settings, and amperage setting should remain constant depending

on the material thickness being run. The condition of the consumables should only change the resulting Kerf very slightly

and should not be a factor.

If very accurate and high-quality-edged plasma cut parts must be produced, it is

recommended that a "Kerf Chart" be developed & kept by the operator listing theoptimum Kerf to be used based on the material thickness to be cut.

This may be accomplished by making successive material cut-offs and checking the

resulting edges, prior to making any production parts. The edge-cut parameters to checkshould include:

o Full Penetration (primarily a function of Torch-to-work off-set distance,

amperage, and feed rate settings).

o Edge squareness: check that maximum bevel is made on scrap; not good part

(primarily a function of correct torch travel/routing).


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o Quality of cut: clean edge with minimum gouges and top and bottom drossformation (primarily a function of the condition of consumables, Torch-to-work

off-set, feed rate, gas pressure and amperage settings).

o Once the above edge-cut parameters are considered satisfactory for production

parts, the operator should make a number of straight cuts partly into the materialfrom an edge, using all the same settings which produced the satisfactory edge-

cut previously. The operator should measure and record the Kerf (gap size)dimension produced on the "Kerf chart" In addition, the "amperage", "gaspressures", and "feed rate" settings should also be recorded on the "Kerf chart"

for future production use of these settings to obtain optimum results when

plasma-cutting parts from the same type and thickness of material.

o THIS PROCESS SHOULD BE REPEATED FOR ALL MATERIAL

THICKNESSES REQUIRING THE SAME DEGREE OF QUALITY AND

ACCURACY OF PRODUCTION PARTS.

o This experimentally determined optimum Kerf dimension must be entered into

Peddimat in order to achieve the optimum quality production parts required.

o Creation and use of chart(s) showing a history of Kerf sizes (based on material

thickness) will help to make future Kerf selection, and entry into Peddimatcorrect, therefore, correct part sizes will result. Without this Kerf information, an

average (default) Kerf setting must be used, possibly resulting in the part size

changing as the Kerf changes.

Summary Notes

Producing accurately sized plasma-arc cut parts with high quality cuts requires all of the

following:

The part must be programmed correctly. The torch must be routed so its path will put the

required "good side" of cut to the right of the torch when viewed from behind the torchas it burns.

The correct Kerf (based on the material thickness to be run) must be entered into

Peddimat. Also, the amperage and gas settings should match the settings used when theKerf was checked. (At time of "Kerf Table" creation).

The correct "Comp." (Left) must be selected in Peddimat.


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OXY-FUEL TORCH

General Safety Information

A number of inherent hazards exist in the use of oxy-fuel welding and cutting apparatus. It is,

therefore, necessary that proper safety and operating procedures are understood prior to using

such apparatus. Read this information thoroughly and carefully before attempting to operateoxy-fuel welding, cutting and heating apparatus. A thorough understanding of the proper safety

and operating procedures minimizes the hazards involved and adds to the pleasure and

efficiency of your work.

The following preliminary safety checklist is the basis for further specific safety informationnoted throughout this manual.

The Work Area

The work area must have a fireproof floor. We recommend concrete floors.

Use heat-resistant shields to protect nearby walls or unprotected flooring from sparksand hot metal.

Maintain adequate ventilation to prevent the concentration of oxygen/fuel gas,

flammable gases and/or toxic fumes. It is important to remember that oxygen itself willnot burn. The presence of pure oxygen, however, serves to accelerate combustion and

causes materials to burn with great intensity. Oil and grease in the presence of oxygen

can ignite and burn violently.

During oxy-fuel processes, use work benches or tables with fireproof tops. Fire bricks

commonly top these surfaces and support the work.

Chain or otherwise secure oxygen and fuel gas cylinders to a wall, bench, post, cylinder

cart, etc. This will protect them from falling and hold them upright.

Protective Apparel

Protect yourself from sparks, flying slag, and flame brilliance at all times. Wear goggles

with tempered lenses shaded 4 or darker to protect eyes from injury and to provide goodvisibility of the work.

Wear protective gloves, sleeves, aprons and shoes to protect skin and clothing from

sparks and slag. Keep all clothing and protective apparel absolutely free of oil or grease.


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Fire Prevention

Practice fire prevention techniques whenever oxy-fuel operations are in progress. A few simple

precautions prevent most fires and minimize damage in the event a fire does occur. Alwayspractice the following rules and safety procedures.

Inspect oxy-fuel apparatus for oil, grease or damaged parts. DO NOT use the oxy-fuelapparatus if oil or grease is present or if damage is evident. Have the oxy-fuel apparatus

cleaned and/or repaired by a qualified repair technician before using it.

Never use oil or grease on or around any oxy-fuel apparatus. Even a trace of oil orgrease can ignite and burn violently in the presence of oxygen.

Keep flames, heat and sparks away from cylinders and hoses.

Flying sparks can travel as much as 35 feet. Move combustibles a safe distance awayfrom areas where oxy-fuel operations are performed.

Use approved heat-resistant shields to protect nearby walls, floors and ceilings.

Have a fire extinguisher of the proper type and size in the work area. Inspect it regularly

to ensure that it is in proper working order. Know how to use it.

Use oxy-fuel equipment only with the gases for which it is intended. DO NOT open an acetylene cylinder valve more than approximately 1 1/2 turns and

preferably no more than 3/4 of a turn. Keep the cylinder wrench, if one is required, onthe cylinder valve so the cylinder may be turned off quickly if necessary.

All gases except acetylene:Open the cylinder valve completely to seal the cylinder

back seal packing.

Never test for gas leaks with a flame. Use an approved leak-detector solution.

When work is complete, inspect the area for possible fires or smoldering materials.

Vision Safety

NEVER LOOK DIRECTLY AT THE FLAME. WEAR GOGGLES WITH

TEMPEREDLENSES SHADED 4 OR DARKER TO PROTECT EYES FROM INJURY

AND TO PROVIDEGOOD VISIBILITY OF THE WORK.

Also, WARNother people in the area NOT TO LOOK DIRECTLYAT THE FLAME, unless

they wear proper eye protection.

For complete eye safety instructions (including recommended lens shade #'s) and other safety

requirements & warnings, be sure to read and follow "Section 1: General Safety Information" ofthe "Victor Oxy-Fuel Welding, Cutting and Heating Guide" (latest revision) which has been

excerpted above and a copy of which is supplied with each machine.

Caution:

If the FDB1500 will be located in an area where the cutting section of the machine will be

directly visible to other persons in the area, Peddinghaus Corporation recommends installingprotective screens or curtains to prevent any inadvertent eye exposure of other workers or

persona passing by.


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Gas Control Panel

The Oxy-fuel torch gas control panel regulates the fuel and Oxygen to the Oxy-fuel torch.

Contents:

1. FUEL HIGH controls

2. FUEL LOW controls

3. CUT OXY gauge

4. OXY HIGH controls

5. OXY LOW controls

6. CUT OXY controls

Note: Also see "Victor Oxy-Fuel Welding, Cutting and Heating Guide" for descriptions and

functional operation of regulators, needle valves and inlet/outlet connections.


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Gas Control Panel Continued

FUEL HIGH controls

1. FUEL HIGH - Incoming high pressure pre-heat fuel controls.

1a. Regulator

1b. Gauge

1c. Flow Control Valve

This further regulates the incoming cutting fuel supply to the Peddinghaus "High" pressure

setting. Fuel high is used primarily for fast pre-heating and to add a boost when first starting acut at an edge or piercing. This regulator may be set up to 25% higher than(2), the Low Pressure

Incoming Fuel Regulator. The setting used is dependent on the cutting gas used, tip size and

material to be cut.

WARNING:

The supply pressure of acetylene gas to the gas control panel should never exceed 15 psi (105 KPa).


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FUEL LOW controls

2. FUEL LOW - Incoming high pressure pre-heat fuel controls.

2a. Regulator

2b. Gauge


This further regulates the incoming cutting fuel supply. The setting depends on the fuel used,

torch tip used, and plate thickness. (See Oxy-Torch Cutting Charts for suggested FUEL LOWpressure settings.)

CUT OXY gauge

3. CUT OXY Gauge

Main cutting Oxygen monitoring gauge. This gauge indicates the Oxygen pressure available at

the torch tip for cutting operations.


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OXY HIGH controls

4. OXY HIGH - Incoming high pressure pre-heat Oxygen controls.

4a. Regulator

4b. Gauge


This further regulates the incoming cutting oxygen supply to the Peddinghaus "High" pressuresetting. It is used primarily for fast pre-heating and piercing (cut-starting applications). This

regulator may be set up to 25% higher than (5), the OXY LOW pressure incoming oxygen

regulator.


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OXY-FUEL TORCH - OXY-TORCH OPERATING GUIDELINES

Pre-Operation

Ensure that your cutting environment and your clothing meet the safety requirements.

Refer to Oxy-Torch Cutting Charts for the type and thickness of material you plan to cut.

Select the gas combination that will create the desired results. Check to see if your gas supplies are adequate for the amount of cutting to be done.

Select the proper torch tips from the Cutting Chart Data. See Oxy-Torch Cutting Charts.

Install the tips in the torch. (See Torch Tip Cleaning and Changing Procedure.)

Operation

When the part is programmed with Peddimat Software, the cutting speeds are automatically sent

to the Fagor CNC controller.

The cutting speed may be adjusted by changing the Fagor Feed rate Adjustment.

Set the torch spacing with the work piece (per spacing adjustment procedure; below.)

Torch Spacing Adjustment:

Turn adjusting collar (1) to adjust the spacing (2)between the torch tip end and the ignitor.

Set the torch tip 1/8" above the bottom level of the

ignitor (2) (one ignitor shown).

(Note: The ignitor(s) also serve as a materialsensing foot).

Torch lighting:

The torch is lit using a 120V primary / 10,000V secondary ignition transformer. The transformer

supplies 10,000 volts to the torch. When it jumps from the torch tip to ground, it creates a sparkto light the gases. The voltage goes to a grounding electrode (igniter), which also serves as a

material sensing foot (one igniter shown above). These grounding locatio

FDB1500-2500 Instruction Manual

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