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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
Introduction Chapter 3 Page 30
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
Introduction Chapter 4 Page 55
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
Hydraulic power unit
All hydraulic equipment is powered by the Hydraulic power unit.
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.
Hydraulic power unit
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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Part exit side (non-datum)
5.
Part exit side right (non-datum)
6.
Part exit side right (non-datum)
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Part exit side (non-datum)
8.
Part exit side (non-datum)
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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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)
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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.
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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.
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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.
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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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Gas Control Panel Continued
FUEL LOW controls
2. FUEL LOW - Incoming high pressure pre-heat fuel controls.
2a. Regulator
2b. Gauge
2c. Flow Control Valve
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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Gas Control Panel Continued
OXY HIGH controls
4. OXY HIGH - Incoming high pressure pre-heat Oxygen controls.
4a. Regulator
4b. Gauge
4c. Flow Control Valve
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