INSTRUCTION MANUAL

Operation/Safety/System Specifications/ Lubrication/Mechanical Maintenance/ Hydraulics/Pneumatics FOR FPB-1500/3C, D or E, FPB-500/3E, or FPB1800/3A PLATE PUNCH AND PLASMA CUTTING (with MARKING) SYSTEM

Peddinghaus Corporation Version #1, Rev. 3, May 19, 2005

YD-2308506

Table of Contents
1. OPERATION
Plasma Torch Set-Up and Info .........................................................................................1-1 to 1-11 Fagor CNC Control Panel Illustration ............................................................................1-12 Fagor CNC Control Panel Switch Description ...................................................1-13 Program Loading and Management Procedures................................................1-19 Program Loading Procedure ................................................................................1-19 Program Management...........................................................................................1-20 Deletion of Program(s) ..........................................................................................1-20 Lock/Unlock Memory............................................................................................1-20 Peddimat Software Programming........................................................................1-20 Main Operator Control Panel Illustration ......................................................................1-22 Daily Usage .............................................................................................................1-23 Start-Up ..................................................................................................................1-23 Principles of System Operation ............................................................................1-25 Manual Operation..................................................................................................1-25 Automatic Operation.............................................................................................1-29 Torch Fault Indicators/Restart Procedure..........................................................1-30 Emergency Action..................................................................................................1-32 Troubleshooting .....................................................................................................1-32 Operator Adjustments/Functional Maintenance................................................1-32 Operator Cutting Process Maintenance Diagram ..............................................1-35 Exhaust Plenum Chamber Scrap-Cart Unloading Info. ....................................1-36 Opposite-Datum Parts Identification Illustration ..............................................1-37

2. UNLOADING & INSTALLATION

Shipping The Components ....................................................................................2-1 Unloading................................................................................................................2-1 Procedures, Cautions, Safety Standards & Weight Data...................................2-1 Machine Set-Up......................................................................................................2-9 Dismantling of Packing .........................................................................................2-9

Cleaning ..................................................................................................................2-9 Hydraulic Power Unit............................................................................................2-9 Optional Equipment ..............................................................................................2-10 Machine Connections ........................................................................................................2-10 Hydraulic Connections ..........................................................................................2-10 Electrical Connections ...........................................................................................2-10 Pneumatic Connections .........................................................................................2-12 Filtration Unit Connections ..................................................................................2-12 HT2000 Plasma Arc Cutting System Connections .............................................2-12 Requesting a Service Technician for a System Start-Up................................................2-14 Smoke Collector Dampener Adjustment.........................................................................2-15 Dust Collector Application Aluminum & Steel............................................................2-16

3. SYSTEM SPECIFICATIONS
Specifications ......................................................................................................................3-1 Material Processing Parameters...........................................................................3-1 Punching Parameters ............................................................................................3-1 Plasma Torch Material Cutting Parameters.......................................................3-4 HT2000 Plasma Torch Maximum Material Piercing Limit ..............................3-4 General Layout Showing Various Machine Features & Specifications............3-5 Material Processing Limits ...................................................................................3-7 Triple-Tooling Punch & Die Specifications.........................................................3-11 Changing Punches And dies..................................................................................3-13 Punch And Die Specifications ...............................................................................3-15 Plasma Torch Adjustment ....................................................................................3-16 Torit Model DFT 2-8 Filtration System Specifications ..................................................3-17 Filters, Accessibility and Cleaning .......................................................................3-17 Filtration System Capacity, Performance & Construction Data ......................3-18 Filtration System Shipping/Additional Information ..........................................3-19 Filter Cartridge Monitoring/Maintenance ..........................................................3-20

4. SYSTEM ASSEMBLY I.D.S

General Arrangement of Standard Equipment ..............................................................4-1 FPB System Component Size & Weight Data Sheet...........................................4-2 Material Path Through FPB & Various Component I.D.s...............................4-3 Emergency Off Buttons & Safety Switches .....................................................................4-4 to 4-7 Fiber Optic Sender/Receiver Operational Information .....................................4-8

5. CONTROL SWITCHES
Y-Axis Switches..............................................................................................................5-1 X-Axis Material Leading-Edge Reference Switch ......................................................5-2 Punch Cylinder Control Switches ....................................................................................5-3 Opposite Datum (Fiber Optic) Control Switch Configuration......................................5-4

6. SAFETY FOR PEDDIMAT SYSTEMS

Training ..............................................................................................................................6-1 Safeguarding Peddimat Systems ......................................................................................6-2 Hazard Identification ........................................................................................................6-4 Hazard Control Strategy...................................................................................................6-4 Supervision .........................................................................................................................6-5 Lockout/Tagout Procedures..................................................................................6-6 Operation ............................................................................................................................6-10 Maintenance (Safety) .........................................................................................................6-11 Set-Up And Tool Changing ...............................................................................................6-12 Warning Signs ....................................................................................................................6-12

7. CARE AND MAINTENANCE

Lubrication .........................................................................................................................7-1 X-Axis Drive Component Lubrication Information.......................................7-3 Y-Axis Drive Component Lubrication Information.......................................7-4 Typical Entry Vertical Material Hold-Down Roller Lubrication .....................7-5 Horizontal Material Datum Clamping Lubrication Information. ....................7-6 Triple-Tooling Mini-Ram Lubrication Information ..........................................7-7

Plenum Chamber Scrap-Cart Wheel Lubrication .............................................7-8 Plasma-Torch/Marker Vertical Travel Lubrication ..........................................7-9 Punch Tooling/Rail Assembly Lubrication Information ...................................7-10 Cone Drive Gear Reducer (30:1 Ratio)................................................................7-11 Ball Screw Assembly Lubrication ........................................................................7-15 Pneumatic Lubrication..........................................................................................7-16 Care And Maintenance Of The Mechanics .....................................................................7-19 Service/Repair Parts ..............................................................................................7-20 Ordering Spare Parts (Order Entry Department) .............................................7-20 Returning Spare Parts For Credit .......................................................................7-21 Assembly Drawings................................................................................................7-21 Fasteners .................................................................................................................7-21 Loctite .....................................................................................................................7-22 Fastener Torques ...................................................................................................7-24 Torque Specifications of Specific Machine Components ...................................7-25 Painting ...................................................................................................................7-29 Care & Maint. of Original Equipment Mfg. Devices .................................................7-30 Cone Drive Gear Reducer .....................................................................................7-30 Hypertherm Plasma-Arc Cutting System Maintenance ....................................7-30 Torit Model DFT 2-8 Filtration System Maintenance .......................................7-32 Care And Maintenance of Hydraulics And Pneumatics ................................................7-34 Cylinders.................................................................................................................7-34 Hose, Tube and Pipe Specifications......................................................................7-35 Hydraulic Power Unit............................................................................................7-36 Pneumatics..............................................................................................................7-37 Care and Maintenance of Electricals ...............................................................................7-39 Care and Maintenance of the Control Console...................................................7-39 Primary Current ....................................................................................................7-39 Interface Axis Servo Drives ..................................................................................7-40 Care and Maintenance of General Components.............................................................7-40 Maintenance Check List....................................................................................................7-40

8. ASSEMBLY DRAWINGS & BILLS OF MATERIAL

INTRODUCTION/MACHINE DESCRIPTION
It is important that all persons supervising, operating or servicing your Peddimat CNC system read and understand this manual; especially Section 6, SAFETY FOR PEDDIMAT SYSTEMS. This manual deals with the mechanical operation and maintenance of your Peddimat CNC system. Some of the features described may be of optional equipment, which you may not have in your system. The Peddinghaus FPB is a machine used for fabricating steel plate. The machine primarily consists of a triple-tooling punch assembly combined with a plasma cutting torch system and an air driven marker. The punch section can be programmed for any selected punch or punch combinations to produce holes or layout marks at any location on the plate to be processed. In addition, the air plasma cutting torch system can be programmed to burn profile shapes from the plate or for cutting the plate to length. The marking system can be programmed to create any string of alphanumeric characters as well as any geometric shape that can be produced by the torch. Optional equipment will have its own manual. All pertinent manuals will be provided for the equipment you are receiving. For information on optional equipment, which is available for your machine, contact your Peddinghaus sales representative. Refer to the separate System Data Sheets provided in the machine electrical enclosure door pocket for the following information: Machine Axis Assignments Machine Tool Miscellaneous Commands Machine G Commands Fagor CNC Control Parameters (P and M) Machine PLC Logic Ladder Diagrams Servo Drive Parameters

PEDDINGHAUS CORPORATION
Peddinghaus products have been marketed throughout the world since 1903. 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 machines and systems for the fabrication of plate and structural steel. Presently, Peddinghaus Corporation manufactures a wide range of manual 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 sold throughout the world market.

Peddinghaus Corporation, 1995 All Rights Reserved

Peddimat Software is a copyright of Peddinghaus Corporation

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 of its or any related equipment.

PEDDINGHAUS CORPORATION 300 N. Washington Avenue Bradley, Illinois 60915 Telephone: (815) 937-3800 Telefax: (815) 937-4003

MACHINE IDENTIFICATION PAGE

MODEL: ________________________________________________________________ SERIAL NUMBER: _______________________________________________________ DATE OF MANUFACTURE: ______________________________________________ CONTROL TYPE/NUMBER: _______________________________________________ DRIVE CONFIGURATION: ________________________________________________ ORIGINAL PURCHASER: _________________________________________________

1. OPERATION
1.1 Torch Alignment, Set-Up, and Adjustments
Prior to cutting with a machine-torch, ensure that the torch is at right angles to the workpiece to get a clean, vertical cut. Use a small square to check torch alignment. The torch squareness alignment should be checked at 90 increments around the torch circumference (0 , 90, & 180). At least three increments of 90 should be checked. See Figure-A below.Also, refer to figures 1.1.9 & 1.1.10 on the following pages for additional information.

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1.1.1 Torch/Marker Height Set-Up/Adjustment Procedure

1-2

1.1.2 Torch Position Relative to Axis Adjustments

1-3

1.1.3

Plasma-Arc Cutting Guidelines / Torch Path Routing

The Peddinghaus FPB 500/3, FPB 1500/3, and the FPB 1800/3 Machines use a Plasma Torch for cutting. The principle of Plasma-Arc Cutting, simply put, uses a high velocity jet of hot ionized gas to cut the material. In this case the gas used is either specially filtered shop air or oxygen. In order to produce the best possible cuts (least bevel and correct sizing) during Plasma-Arc cutting the following guidelines should be used.

1.1.3.1 Torch Path Routing

The cut produced by a Plasma Torch has a good side (approx. 2 to 4 degree bevel) and a bevel side (approx. 7 to 9 degree bevel). The placement of these sides in relationship to the torch travel is dependent on the Swirl Ring direction (clockwise is standard). All Peddinghaus equipment is supplied with the standard Clockwise Swirl Ring. What this will produce is the Good Side to the right of the torch when viewed from behind. This placement is shown in Figure 1.1.13.1 (page 1-23). This data must be taken into consideration when programming parts to be run on an FPB 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. If leading edge is desired to be good side, then cutoff must be performed from non-datum side to datum side. Making A Double Trim Cut: A double trim cut is a cutoff made with the torch traveling from the 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 Engineering specifies 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. (See pages 1-27 for illustration). ** 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 Figure 1.1.13.1 Correct Plasma-Torch-Path Routing for Best Cutting Results, page 1-23). ** 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 Figure 1.1.13.1 Correct Plasma-Torch-Path Routing for Best Cutting Results, page 1-23).

1-4

1.1.3.2

Correct Plasma-Torch-Path Routing for Best Cutting Results

1-5

1.1.3.3 Kerf & Cutter Compensation Definitions & Data

The term Kerf refers to the gap that is removed as molten metal during the cutting process. This gap is approx. 1/8 (See Optional Kerf Changes on Page 1-25 & Table A, Page 1-28) 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 Figure 1.1.13.3 Illustration below). IT IS IMPORTANT THAT THE KERF DIMENSION ENTERED IS ACCURATE. * With cutter comp. 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. Figure 1.1.13.3 Cutter Comp. Illustration & Setting Information

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1.1.3.4 Optional Kerf Changes

Determination of Optimum Kerf parameters via successive cut/Kerf checks, recording this Kerf value, & changing the default kerf setting in Peddimat to this newly determined value in order to obtain optimum edge-cut quality & very accurately sized cut parts. 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 the optimum 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 check should include: * Full Penetration (primarily a function of Torch-to-work off-set distance, amperage, & feed rate settings). * Edge squareness.....check that maximum bevel is made on scrap; not good part (primarily a function of correct torch travel/routing). * Quality of cut....clean edge with minimum gouges & top & bottom dross formation (primarily a function of the condition of consumables, Torch-to-work off-set, feed rate, gas pressure & amperage settings). * Once the above checked edge-cut parameters are considered satisfactory for production parts, the operator should make a number of straight cuts partly into the material from an edge, using all the same settings which produced the satisfactory edge-cut previously. The operator should measure & record the Kerf (gap size) dimension produced on the Kerf chart In addition, the amperage, gas pressures, & 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 & thickness of material. * THIS PROCESS SHOULD BE REPEATED FOR ALL MATERIAL THICKNESSES REQUIRING THE SAME DEGREE OF QUALITY & ACCURACY OF PRODUCTION PARTS. This experimentally determined optimum Kerf dimension must be entered into Peddimat in order to achieve the optimum quality production parts required.

1-7

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 Peddimat correct.....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. A few blank Kerf charts have been provided at the end of this chapter for your convenience. Your machine operator should reproduce as many copies as required. 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 torch as 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 the Kerf was checked. (At time of Kerf Table creation). * The correct Comp. (Left) must be selected in Peddimat.

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1.1.4 Double-Trim Cut Specs & Torch-Travel To Kerf Relationship

NOTE: Peddinghaus Engineering specifies 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. Ref. - Double Trim Cut defined below.

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1.1.5 Kerf Definition, Size Range, and Cut-Edge Squareness Data

Kerf: Slit made in workpiece by cutting torch. NOTE: The actual kerf created during plasma torch cutting is a function of many variables such as cutting speed, torch stand-off height, torch-to-work angle, amperage setting, cutting gas quality and pressure settings, condition of consumables, type and uniformity of material being cut, amount of play in machine axes transporting the material and torch, etc., however, once all settings and adjustments have been made, the kerf obtained should be fairly consistent for similar cuts in same material. Squareness of Cut Edge: Good Side: 2- 4 Typical Other Side: 7 - 9 Typical

KERF SIZE RANGE: TABLE A

Kerf Size Range (metric) NOZZLE ORIFICE DIA. (metric) CURRENT SETTINGS (Amps)

0.100 - 0.130 (2,5mm-3,3mm) 0.090 - 0.120 (2,3mm - 3,0mm)

0.087 (2,2mm) 0.059 (1,5mm)

200 100

THIS KERF GUIDE TABLE PROVIDED FOR GENERAL PURPOSE ONLY.

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1.1.5.1 Plasma-Torch Cutting & Piercing Information

CUTTING: Start Cutting from the edge of the workpiece, unless you must pierce. For tips on piercing, refer to the Piercing section. When cutting, make sure that the sparks are coming out of the bottom of the workpiece. If not, check for the following: * If the sparks are spraying on top of the workpiece, the torch may be moving too fast. Check the Cutting Charts (pages 1-17 and 1-20) for the correct travel speeds. The optimum travel speed is generally just slightly under the speed that causes the arc to rooster tail off of the workpiece. * If there is not sufficient power to fully penetrate the workpiece, reduce the travel speed. If this does not work, stop cutting, and re-check the cutting chart specifications. PIERCING: THE HT2000 CAN PIERCE METALS UP TO A THICKNESS OF (1) INCH (25mm). Set the torch-to-work distance (standoff height) so that the shield cap is 3/8 (10mm) or more away from the workpiece. See Torch Stand-Off Height Data (page 3 -20) for setting confirmation of dimension required. This piercing standoff height is automatically enabled by the software whenever a piercing operation is programmed. Note: For initial torch standoff height set-up procedure, see Figure 1.1.9. (page 1-14). Ensure the machine delay on the power supply is set to the recommended motion time delay (refer to the Cutting Charts - pages 1-17 & 1-20) in order for the metal to be pierced completely before the travel motion begins. NOTE: THIS PARAMETER HAS BEEN PRESET BY THE FPB SOFTWARE - LEAVE SET AT 0. Position the torch directly over the workpiece juncture/cut line to be pierced. The workpiece can now be pierced.

1-11

1.2 Fagor CNC Control Panel Illustration

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1.2.1 Fagor CNC Control Panel Switch Description

NOTE: The number preceding each item listed below corresponds to the same number (#) indicated on CNC Control Panel Illustration, PANEL-B, previous page. 0. SCREEN Displays the following information: Operating mode listing Active operation mode Program and block being executed Program and block being written Map of programs contained in memory Coordinate values of the axes Following error Feedrate, speed of the spindle, active functions Tool table Error Codes Dialogue with the operator 1. FUNCTION KEYS (F1 - F7) Their meaning will be displayed just above each key after one of the ten different operating modes have been selected. ALPHANUMERIC KEYBOARD Will be used in developing, recalling, and editing part programs. ENTER Allows information to be entered in the CNC memory, etc. RECALL To access a program, a block within a program, etc. OP MODE Displays the Operating Modes list on the screen. (This is the first step in accessing any of them.) DELETE Erases complete programs or program blocks. It can also erase the table of decoded M functions. RESET To return the CNC to the initial conditions and recognize new machine parameter values, decoded M functions, etc.

2. 3. 4. 5.

6.

7.

1-13

8. 9. 10.

CL To delete characters one by one during the editing process, etc. INS Key which allows characters to be inserted during the editing of a program block. ARROW KEYS Used in moving the cursor in one of four different directions. (Left / Right / Horizontally / or Vertically). PAGE UP & PAGE DOWN KEYS SP Reserves a space between characters of a comment. CAPS Allows characters to be edited in capitals. SHIFT Allows characters to be edited, which are found on keys with double meaning.

11. 12.

13. 14. 15.

JOG These are for manual displacement of the axes. RAPID FEED Accelerated feed of an axis in JOG mode can be obtained while pressing this key. SWITCH (M.F.0.) Which allows a % variation of the programmed feed and to choose the different ways of working in the MANUAL MODE (continuous, incremental, electronic handwheel). SPINDLE OPERATING KEYS Allow the spindle to be put into OPERATION and to STOP it, in the MANUAL operating mode. The + (plus) and - (minus) keys allow a % variation of the programmed turning speed of the spindle during operation. START Cycle Start is the GREEN key. STOP Cycle Stop is the RED key. The control stops the execution of the block in progress but maintains synchronism with the machine. To resume the program, press Cycle Start.

16.

17. 18.

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1.2.1.1 Operating Modes

The Fagor 8025 GP CNC has 10 different operating modes: 0 1 2 3 AUTOMATIC Execution of programs in a continuous cycle. SINGLE BLOCK Execution of part programs block by block. PLAY-BACK Creation of a program in memory while the machine is being operated manually. TEACH-IN Creation and execution of a block without entering it into memory Creation, execution, and entering of a block into memory; thus a program is created while being executed block by block. 4 5 DRY RUN To check programs before the actual execution of the first part is initiated. JOG/ZERO SETTING Manual movement of the machine Machine-reference Pre-setting of any value & zero setting of the axis Entering and executing of F, S, M Setting initial conditions of the tool magazine Handwheel operation EDITING Creation, modification and checking of blocks, programs and subroutines. INPUT-OUTPUT Transferring programs or machine-parameters from/to peripherals. TOOL OFFSETS Input, modifications and checking of the dimensions (radius and length) of up to 100 tools and of zero offsets (G53-G59).

7 8

1-15

SPECIAL MODES General testing of the CNC Verification of inputs and outputs Setting of decoded M functions Setting of machine parameters Input of values for leadscrew error compensation Operate with the PLC

* By using these OPERATING MODES, it is possible to program the Fagor control to manufacture parts in an automatic sequence or manually through a program, block by block. To obtain these operating modes: Press Operate Mode (OP). The list of 10 modes will appear on the screen. Enter the number of the desired operating mode (0 - 9).

1.2.1.2 Selection Of The Automatic Operating Mode

1. 2. Press Operate Mode (OP). The list of the 10 operating modes are then displayed on the screen. Press the 0 key - AUTOMATIC. The standard display corresponding to this operating mode appears in the upper left-hand section of the screen. The message AUTOMATIC followed by the number of the program Pxxxx and the number of the first block to be executed Nxxxx appears on the screen.

NOTE: This mode will be used almost exclusively for fabrication.

1.2.1.3 Selection Of The Program To Be Executed

Use this procedure to select a program number other than that appearing on the screen: 1. 2. 3. Press the P key. Enter the number of the desired program. Press Recall

If it exists, the new program selected will appear on the screen. If it does not, the screen will display: N*.

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1.2.1.4 Selection Of The First Block To Be Executed

Once a program has been selected, the number of the first block to be executed appears to the right of the program number. To begin with a different block, use the following procedure: 1. 2. 3. Press the N key. Enter the number of the block. Press Recall.

The new number is displayed on the screen together with the contents of this block and those of the later blocks.

(WARNING): AFTER EXECUTION OF NUMBER/RECALL, THE CONTROL IS RESET TO INITIAL CONDITIONS.

1.2.1.5 Display Of The Contents Of The Blocks

To display the contents of the blocks prior to or subsequent to those appearing on the screen: 1. 2. Press the Cursor Up key. The previous blocks are displayed. Press the Cursor Down key. The later blocks are displayed.

NOTE: The program always starts with the block whose number appears to the right of the program number, irrespective of which ones are displayed on the screen.

1.2.1.6 Start Cycle

Press Cycle Start. Once the program and block number have been selected, press this key to execute the program. At this time the program will continue block by block until further action is taken.

1.2.1.7 Stop Cycle

1. 2. Press Cycle Stop. The Control stops the execution of the block in progress. To resume the cycle, press Cycle Start.

3.

The cycle is also stopped by:

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a. b. c. d.

Code M00, M02, M30, M06. (M06 depending on parameter P601 (8)). Code M01 when the appropriate input is activated. The external signal FEED-HOLD (The cycle continues when the signal disappears). The external signal EMERGENCY STOP. (In this case, the program must be restarted, since the Control is reset to the initial state).

1.2.1.8 Changing The Operating Mode

At any time during the execution of the automatic cycle a transfer may be made to the Single Block operation mode. To do this: 1. 2. Press Operate Mode (OP). The operating modes list will appear on the screen. Press the 1 key - SINGLE BLOCK.

NOTE: If any number other than 1 is depressed, the Control will revert to the Automatic state.

1.2.1.9 Deletion Of A Complete Program

1. 2. 3. 4. 5. Press Operation Mode (OP). The ten operating modes will appear again on the screen. Select mode 6 - Editing. Press F3 - Prog Mapping. A list of up to 14 programs in memory appears on the screen as well as the number of characters used and those remaining available. Press Delete. The message Delete Program will appear on the screen. Key in the number of the program to be deleted, check the number. If the number is correct, press Enter, if the number is not correct, press CL key. (This key cancels the number). Input the correct number and press Enter. If no program is required to be deleted once the Delete key has been pressed, press Operate Mode (OP).

6.

NOTE: If there are more than 14 programs stored in memory, the one to be deleted may not appear on the screen. By operating the Arrow keys either up or down, the various programs may be moved backward or forward until the desired program appears.

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1.2.1.10 Change of Program Number

1. 2. 3. 4. 5. 6. Press Operating Mode (OP). The select mode 6 - Editing at which time the keys to operate in this mode will appear on the screen. Press F6 - Rename. The screen will display: OLD:P. Key in the existing number of the program whose number is to be changed. It will be displayed to the right of P. Press Enter. The screen will then display: NEW: P. Key in the new number allocated to this program. It will be displayed to the right of P. Press Enter. The change of number has been completed.

1.3 Program Loading and Management Procedures

1.3.1 Program Loading Procedure
1. 2. 3. Select Operate Mode (OP). (Panel B, #5); this will display the main menu of the control. Press key 7 to select the input/output mode. Select 2, Input from General Device. Key in program # and press Enter. If there is a program with this number the screen will ask to delete the program. a. b. 4. Press Y for yes. Press N for no, CNC will shift back to step #2.

Data can now be transmitted from IBM/Compatible PC. The CRT display will indicate Receiving until the transmission is complete or an error occurs.

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1.3.2 Program Management

1. 2. Select Operate Mode (OP), (Panel B, #5); this will display the main menu of the control. Press key 6, to select the Editing mode. Press F3- Program Mapping (Panel B, #1). A list of up to 14 programs in memory will appear on the screen as well as the number of characters used and number remaining.

1.3.3 Deletion Of Program(s)

1. 2. Select Delete, (Panel B, #6). If you wish to remove a single program from memory, enter the program #, then press Enter. Select Delete, (Panel B, #6). If you wish to remove all programs, key in the number 99999 when Delete Program is displayed. Press Enter then Y. This removes all programs from memory. If you choose not to, press N.

1.3.4 Lock/Unlock Memory

In the event you are able to view the stored programs but are unable to delete or alter them, the part program memory may be locked. To unlock memory, key in the letters MKJIN followed by Enter.

1.3.5 Peddimat Software Programming

The Peddimat Programming system was developed to greatly enhance system efficiency and productivity. For more information, refer to your Peddimat Software Programming Manual provided with your machine.

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NOTES:

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1.4 Main Operator Control Panel Illustration

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1.4.1 Daily Usage

To maintain accurate and reliable performance of your Peddinghaus Peddimat CNC system, specific maintenance practices and procedures must be followed. The following sections deal with safety and mechanical operation.

1.4.1.1 General
Use the information contained in this manual to prevent injury to those persons supervising, operating, or servicing your Peddimat CNC system. Also be certain to read the Safety Manual For Peddimat CNC Systems, Peddimat Software Programming Manual and any other literature provided to you by Peddinghaus Corporation.

1.4.1.2 Housekeeping
The area around the Peddimat CNC system should be maintained in a clean and uncluttered condition. Punch slugs and scrap metal should be removed from the floor to prevent any accidental loss of footing. If additional equipment is used in conjunction with or in proximity to this Peddinghaus equipment, then it is the responsibility of the users manager to identify potential hazards and provide adequate warning signs, instruction, and point of operation safety. The controls should be kept clean and readable, and should not be obstructed in any manner. All oil and grease should be kept off the floor, the control areas, and areas of the Peddimat CNC system which are not designated as to be oiled or greased. The area around the hydraulic reservoir and hydraulic components should be kept clean of oil, and any leakage must be repaired immediately. The machine should be inspected daily for loose fasteners or damaged equipment. These should be repaired before operating the Peddimat CNC system.

1.4.2 Start Up

All emergency OFF buttons on the machine must be enabled. (Refer to Figure 4.2, page 4 - 5). The Main Power Disconnect on the machine junction box must be ON. (Refer to Figure 4.2, page 4-5). Switch the CNC control on with the Power On button (Panel A, #1B). Please wait until data appears on the video screen.

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Turn on the gases required for the particular cutting to be done. See section Turn Gases On (page 1-10) for step by step instructions, and be sure you have completed and complied with all instructions given in Pre-Operation: part of Section 1.1.5, Torch Operating Guidelines (page 1-10) before continuing. Next, Turn on Power Supply & Adjust Current, Adjust Preflow Gases, and Adjust Cut Flow Gases as directed in named sections of Section 1.1.5, Torch Operating Guidelines (page 1-10) At this point, select the operating mode from the Fagor CNC Controller. (Refer to PANELB #5, Page 1-34). Any optional equipment must be checked for controls and safety devices.

1.4.2.1 Checking Safety Devices (CAUTION): PRIOR TO PUTTING YOUR PEDDIMAT CNC SYSTEM IN OPERATION, WHETHER IT BE AT THE BEGINNING OF THE SHIFT OR STARTUP AFTER BREAK, THE FUNCTIONALITY OF THE BELOW DESCRIBED SAFETY DEVICES MUST BE CONFIRMED. FAILURE TO DO SO CAN CAUSE SERIOUS INJURY OR EVEN DEATH.

With the machine power ON and the horizontal clamps also activated, the flashing red light must be operating. (See page 4-5). There are four (4) Emergency Stop Buttons on the standard equipped model FPB (See page 4-5 for locations). Check each one independently. Press an Emergency Stop Button. The machine operation should stop. Pull the button out to reset it. Press the Power On button to start the system again. Repeat this procedure for every Emergency Stop Button on the machine. Any optional equipment purchased through Peddinghaus or other sources should be checked via their independent procedures.

1-24

1.4.3 Principles of System Operation

1.4.3.1 Loading The Material Onto The Infeed Transfer Module
The plate material must be loaded onto the infeed transfer module so that the datum edge of material is lined up squarely against the fixed datum rollers on the FPB, thereby insuring correct material-to-machine alignment and location of all processing work performed. The leading edge of the plate material must be driven far enough into the entry side of the machine to be past both the vertical and horizontal entry material clamping stations; using selector switch ENTRY-FWD/REV (Panel A, #5C) for the Peddinghaus roller-transfer modules. Follow the same material squaring-up procedure if manually loading the machine. At this point, select machine mode of operation; either Manual or Automatic. NOTE: The number -letter combination enclosed in parenthesis (#L) refers to the number-letter combination identifying each switch/push button on Figure Panel-A, Main Operator Control Panel, which appears at the beginning of Section 1.4.

1.4.4 Manual Operation

NOTE: The number-letter combination preceding each item listed below corresponds to the same number-letter combination indicated on Panel A, page 1-44, push button/switch/indicators. 1A. EMERGENCY STOP (E-STOP) This switch will be used in the event an Emergency condition exists. This includes anything that may be threatening; from bodily injury to machine damage. POWER ON Will be used to start machine by activating system power supplies. POWER OFF Will be used to stop machine by deactivating system power supplies. TORCH MAINTENANCE Is used to indicate when the plasma torch consumables require changing. (Typical interval is as follows: for the HT2000 Plasma System-approximately 24 hours or 2000 ignitions). Switch light will flash as indicator. Depressing switch will reset counter/timer after torch components have been changed.

1B. 1C. 1D.

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2A.

PUNCH JOG/UP-DOWN Is active when CNC is in axis jog mode. This switch is used primarily to check punch/die alignment. (Note: Hydraulic pump will shut off when punch reaches bottom of stroke in this mode. It will restart when UP is actuated). AUTO Selects the automatic punch stroke cycle. When activated, the punch stroke will perform either a full stroke punch cycle or layout as determined by the tool operation code. This is generally selected by the part program in the CNC Automatic cycle mode. LAYOUT Selects the layout marking cycle. When activated, the punch stroke will perform a layout punch cycle regardless of the tool operation code during a machine Automatic cycle.

2B.

2C.

NOTE: DEPTH OF MARK IS INFINITELY ADJUSTABLE BY ROTATING THE FINE-ADJUSTMENT PROXIMITY SWITCH MOUNTING BRACKET, EITHER UP OR DOWN UNTIL DESIRED DEPTH OF MARK IS ACHIEVED.
Remember: Whichever mode is selected (Auto or Layout), the corresponding pushbutton will be illuminated. 2D. OVERTRAVEL/ TOOLFAULT (Dual Function Button) OVERTRAVEL Indicates that an axis overtravel limit has been reached. Jog axis affected in opposite direction of overtravel to correct. TOOL FAULT (Flashing Light) Operator alert indicating a No Punch Condition exists, due to a blocked fiber-optic light signal within the triple-tooling punch housing. MARK OFF Pushbutton is used to override a programmed part marking operation. This gives the operator a choice to mark the part or not without re-programming. AIR LOW Is used to indicate the system air pressure is insufficient to operate the machine properly. VAC FAIL Is used to indicate the punch slug vacuum system may not be operating properly. Determine fault area and correct before continued operation. SAFE ZONE Indicates that the machine safety guard zone has been breached. Check machine area and correct condition, both this pushbutton and Cycle Start must be depressed before the cycle may continue.

3A.

3B. 3C.

3D.

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4A. TORCH AUTO Allows the automatic torch to material height as determined by the part program. 4B. TORCH LOW Allows the manual override of the torch to material height. This will set the torch tip at its lowest position which is approximately 1/8 from the material surface.

4C.

TORCH MED Allows the manual override of the torch to material height. This will set the torch tip at its middle position which is approximately 1/4 from the material surface. TORCH HIGH Allows the manual override of the torch to material height. This will set the torch tip at its highest position which is approximately 3/8 from the material surface. This position is generally considered for material piercing, not cutting. TORCH REPOSITION ENABLE/ PURGE OFF TORCH REPO ENABLE Is used in the event the plasma torch has attempted to arc transfer during an automatic cycle and failed. Conditions that may cause this are things like bent or distorted material, a cutout in the material, or other material related irregularities. If this occurs, press CYCLE STOP and set % FEEDRATE switch to 2%. Depress the TORCH REPOSITION ENABLE switch followed by CYCLE START. This will allow the torch to proceed toward the edge of the material being processed. When at this proximity, set % FEEDRATE switch to 0. Depress the TORCH RESTART pushbutton as described below and wait for arc transfer. Once this has occurred, turn % FEEDRATE switch back to its normal maximum run position. At this time normal cutting operations should resume. PURGE OFF Pressing this button allows the operator to override the timed run-on cycle programmed for the dust/fume collection system, and to shut it down early if he desires. TORCH RESTART Allows for restart of the torch in the event arc transfer has failed or was lost during cutting. (WARNING! Before attempting to restart, determine the cause of the fault condition). This may indicate torch damage, torch distance to material problem, slag/metal shorting tip of torch to material, Hypertherm power is off, or other related problems. ENTRY / FWD-REV Controls manual positioning of material into and away from the infeed side of the machine. EXIT / FWD-REV Controls manual positioning of material away from or into the outfeed side of the machine. NOTE: When material is clamped in the machine, entry or exit work areas, this will disable either or both of these roller transfer control switches.

4D.

5A.

5B.

5C.

5D.

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6A.

UNLOAD Allows manual cycling of the unload drop table. By momentarily depressing the switch and releasing, the table will drop and remain down. Depress once again momentarily to return table to its normal upright operating position. It the table is desired to remain in the up position for any reason, depress the switch and hold down for approximately 3 seconds. This will latch the table in the up position. Depress once again momentarily to unlatch this mode. A more thorough description of these modes is described under the AUTOMATIC OPERATION section to follow. NOTE: It is not advisable to run the plasma torch when table is in the down position, as smoke and other particulate will not be extracted by the systems air cleaning system. Machine damage may occur.

6B.

HORIZ. CLAMPS Cycles the horizontal material clamps, both infeed and outfeed. This is helpful in initially squaring plate material to the machine datum line. It is recommended to do this especially for larger/heavier stock to be processed. CYCLE START Provides remote cycle starting of selected automatic cycles. CYCLE STOP Provides remote cycle stopping of selected automatic cycles. NOTE: The fagor CNC controller must be in the Jog mode prior to selection of manual clamping commands. To enter the Jog mode, press OP Mode (Panel B, #5) which brings up the main menu selections on display; then select and press #5 (Jog) to activate the jog mode. The display will now show X and Y axis position data. During manual operation, material can be Jogged in the X axis under CNC control, only after the horizontal clamps are engaged (step 1), thereby allowing the vertical pinch-rollers to be activated (step 2). This applies to either entry or exit clamping stations. The specific commands required to activate these clamping functions are as follows:

6C. 6D.

CLAMPING FUNCTIONS Entry Side: M Code Horizontal Infeed: M52 Vertical Infeed: M50 Exit Side: M Code Horizontal Outfeed: M54 Vertical Outfeed: M56

Step 1 Step 2

1-28

Input As Follows: Press key M followed by digits (i.e. 52); and then press Cycle Start (Panel B, #17). As each key-stroke is entered, it will be displayed along the lower left-hand corner of the screen (already displaying X, and Y axis position data). Up to eight (8) M codes may be entered at one time: The unclamping functions are as follows:

UN-CLAMPING FUNCTIONS Entry Side: M Code Horizontal Infeed: M53 Vertical Infeed: M51 Exit Side: M Code Horizontal Outfeed: M55 Vertical Outfeed: M57

Step 1 Step 2

(NOTICE): FOR ADDITIONAL MACHINE OPERATIONAL CODES (M CODES) AND ADDITIONAL PROGRAMMABLE CONTROLLER DATA (PLC LOGIC), REFER TO DOCUMENTATION PLACED IN THE POCKET OF THE MAIN MACHINE ELECTRICAL ENCLOSURE.

1.4.5 Automatic Operation

Position material into machine with powered rolling transfers or manually.

NOTE: The part program will automatically select a punch operation or layout mark. If the Layout mode is selected, all subsequent punch or layout operations will be processed as a layout mark.

Select and press OP Mode (Panel B, #5, pages 1-34) and press key # 0, which selects the Automatic operation mode.

To select the desired program from memory, press P, input the program # (5 digits maximum), and then press Recall (Panel B, #4) The selected program is now ready to run. Exit Table Drop Operation Options Mode 1: (CYCLICAL TABLE -DROP OPTION) On machine power up, exit table will drop after each program code M64. Mode 2: (TABLE-DROP REMAINS IN DOWN POSITION OPTION) Depress UNLOAD pushbutton (Panel A, #6A) momentarily. Unload table will remain in drop position until toggling (depressing) of the UNLOAD pushbutton is executed again.

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* Mode 3: (TABLE-DROP REMAINS IN UP POSITION OPTION) Depress UNLOAD pushbutton (PANEL A, #6A) for approximately 3 seconds and release. Table will momentarily drop and return to up position. In this mode the drop table will remain in the up position for all cutting cycles. (M64 will be ignored). To disable this mode momentarily depress the Table Drop pushbutton once again. Mode I will now be executed. Press Cycle Start (Panel B, #17) to start automatic operation of the machine as programmed. Immediately after initiating Cycle Start (Panel B, #17, page 1-34), the machine will begin processing by clamping the material, first horizontally, then vertically. Referencing of the x and y axis occurs next. The x axis zero reference switch (shown in Figure Layout, page 3-8) is used to detect the leading edge of the material to be processed. The Y axis zero reference switch (shown in Figure 5.1, page 5-1) positions the center punch head to a pre-set distance of 3.0(76,2mm) from the material datum edge. The Fagor CNC will have a program stop at the completion of each part program to allow for the removal of the completed part. Press the Cycle Start key (Panel B, #17) to restart the program.

1.4.6 Torch Fault Indicators/Restart Procedure

Torch fault indication and torch inspection procedure:

* When a torch fault occurs, the Torch Fault/Restart light activates (Panel-A, #5B,
page 1-44) * The Torch Fault/Restart pushbutton (Panel-A, #5B) may be activated to restart the torch.

Flashing Torch Maintenance light indication: * Time out is shown by a one (1) second interval flashing of the Torch Maintenance light (PANEL-A, #D1). **Change the torch electrode and any other worn parts. (Refer to Section 1.1.17 for consumable inspection & changing procedures. In addition, refer to the cutting charts, Sections 1.1.11.1 through 1.1.11.4., for pictorial descriptions and part numbers required to change the consumable parts; for the particular amp setting you may be cutting with). Press the Torch Maintenance pushbutton once more when finished, to reset the machine. (MAXIMUM TIME IS AS FOLLOWS: For the HT2000 Plasma System, approximately 24 hours or 2,000 ignitions; for the MAX200 Plasma System, approximately 12 hours or 1000 ignitions).

1-30

(WARNING): WORK ON THE PLASMA TORCH UNIT WITH THE POWER OFF ONLY! FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES BEFORE PROCEEDING. REFER TO SECTION 6.5.1. FOR DETAILS.

** Note: Genuine Hypertherm parts are the factory recommended replacement parts for your HT2000 system. Any damage caused by the use of other than genuine Hypertherm parts is NOT covered by the Hypertherm warranty. Flashing Torch Restart (Ignition off) fault indication: * Ignition out (off) is shown by a one (1) second interval flashing of the Torch Restart light (PANEL-A, #B5). One of the causes of achieving and/or maintaining plasma torch ignition is the condition of the consumables. Change torch electroce and any other worn parts, as explained previously--being sure to observe all cautions and notes specified. Press the Torch Maintenance push-button when finished to reset the machine.

(WARNING): FAILURE TO CHANGE WORN PARTS MAY RESULT IN TORCH DAMAGE)

Torch Re-Start Procedure

In the event the plasma torch fails to achieve arc transfer during start-up, use the following procedure: * Check torch position in relation to material. Torch should be located at material edge. * Make certain no obstructions are interfering with torch position (i.e., slag, burrs, etc.) * Adjust % Feedrate switch to 10% position. * Depress Torch/Re-Start pushbutton (Panel-A, #5B). Allow approximately three (3) seconds for torch to light. * Once torch is attempting to light, momentarily press Torch Repo Enable pushbutton (Panel-A, #5A). This will allow machine to continue motion toward material to achieve an arc. NOTE: Holding Torch Repo Enable pushbutton (Panel-A, #5A), allows axis motion and overrides punching and cutting operating functions. * Allow approximately 2-3 seconds, then return % Feedrateswitch to original maximum position.

1-31

* Provided arc has been achieved, the machine will continue processing the programmed part.

1.4.7 Emergency Action

In case of an emergency or malfunction, push E-Stop switch (Panel A, #1A) or any emergency stop switch located around the machine (see Figure 4.2, pages 4-5 in section 4.2). This shuts off all electrical and hydraulic power immediately.

Power should only be re-applied after the problem or fault condition is resolved. FAILURE TO DO SO MAY RESULT IN BODILY INJURY OR DEATH.

1.4.8 Troubleshooting
Control turns On but no axis drive occurs. Possible causes are:

* Top of stroke proximity switch is not made. (Refer to Figure 5-3, page 5-3). * * * * * Drives are in a fault mode. Drives are missing a power phase Control gives the following error, 70 (x-axis), 71 (y-axis). Possible causes are: The axis has a mechanical restriction. The control has no encoder feedback. The drive is not responding to velocity output.

Note: For further help in solving any problems, call Peddinghaus Service Department, 7:00 am to 7:00 pm., Central Standard Time, at (815-937-3800).

1.4.9 Operator Adjustments/Functional Maintenance

1.4.9.1 Adjustments to Hydraulic Clamping Pressure
The operator may adjust the hydraulic pressure on the horizontal material clamps, if processing very thin plates, for example, to prevent crushing the material. He may also adjust the hydraulic pressure on the vertical pinch (traction) rollers, if the downward force is too powerful on certain materials and causes embossing of the wheel pattern on the material surface. Both of these adjustments may be made via the pressure reducers provided for each clamping function.

1-32

1.4.9.2 Operator Functional Processing Maintenance

The operator who incurs a very high percentage of cutting arc usage (and only minor punching time) may experience an extreme amount of plasma dross build-up on certain machine parts around the torch. For those processing situations described above, or if dross build-up is excessive, and to minimize the time spent removing this slag/dross, it is recommended that the operator spray the build-up areas; particularly the sides of the air gap slot and all exposed vertical metal panels located on the exhaust chamber directly under the torch path, with WELD-KLEEN 350 (or equivalent) anti-spatter spray. (Refer to Figure 1.4.10, Page 1-57).

1.4.9.3 Exhaust Chamber Scrap Cart Monitoring/Emptying

The exhaust chamber has a removable cart into which small cut-off and scrap pieces fall during plasma cutting operations. The operator should monitor the cart capacity periodically and empty the contents as required. It is recommended that the cart be removed and emptied before it becomes completely full; thereby making it safer and easier to handle. Lifting holes have been provided in the cart walls to facilitate the lifting and dumping of the cart contents. (See Figure 1.4.11 on Page 1-58). Be sure to practice safe handling procedures during cart unloading to avoid accidents and injuries. Refer to Sections 2 and 6 of this manual for further guidance.

1.4.9.4 Opposite-Datum Feature

The Opposite-Datum Feature has been designed into the machine for the accurate location of holes punched from the non datum edge of the material to be processed. This feature may be invoked through the Peddimat software. This is a photo-electric switch actuated feature (See Figure #1.4.12. pages 1-59) and its function is based on the theory that at the precise moment the photo-electric switch is actuated, the center of the middle punch, P2, (of the triple-tooling punch set) is located exactly 5 (127mm) inboard of the Opposite Datum material edge. The adjustable-mounted actuating reflective tape bracket is initially set-up based on the above-cited criteria.

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1.4.9.5 Periodic Cleaning of Exit Side Pinch/Drive Rollers

Periodically clean-off accumulated debris from exit side upper pinch roller and lower material drive roller with a wire brush. Frequency of cleaning is dependent on amount of plasma cutting, e.g. clean more often during heavy cutting duty cycles. Not performing this periodic cleaning could result in causing poor grounding and therefore prevent establishment of the plasma arc.

1.4.9.6 Torit Filtration System Installer/Operator Checklist

The following points are critical to the optimum performance of the FPB filtration system and must be checked in order to insure proper operation.

Supply Air

* A separate air supply must be furnished to the Torit filtration system capable of delivering clean & dry air at a pressure of 90-100 psig in order for the self-cleaning feature to operate at maximum efficiency. * Self Cleaning System Timer Control Settings Check the Upper-right hand corner of the timer control box to see if the plug-on jumper wire is pushed onto the correctly numbered pin connector which coincides with the number of cleaning valves actually present in your model filtration system. Check the Upper-left hand corner of the timer control box for the correct ON-TIME & OFF-TIME settings. Rotate pot until desired setting is obtained. OFF-TIME setting--this should be set at 5 seconds. ON-TIME setting--this should be set at between 0.05 and 0.10 seconds. Electric Power (110-V) Supplied to Cleaning System It is recommended that the self-cleaning system be wired so that power is supplied to it at all times when power is supplied to the FPB. This will insure maximum filter cleaning time (down time purging) and therefore result in optimum filter life.

* * * *

1-34

1.4.10 Operator Cutting Process Maintenance Diagram

1-35

1.4.11 Exhaust Plenum Chamber Scrap-Cart Unloading Information

1-36

1.4.12 Opposite-Datum Parts Identification Illustration

1-37

1-38

2. UNLOADING & INSTALLATION

2.1 Shipping The Components
To facilitate the shipment and installation of your Peddimat system, it has been dismantled into sub-assemblies. The various component groups, sub-assemblies or optional equipment are identified as follows: Main Machine Structure Infeed Roller Transfer Module Sections. Outfeed Roller Transfer Module Sections. Hypertherm Machine Torch Plasma Arc Cutting System. Torit Filtration System (With Flex-Ducting, and Connectors). Hydraulic Power Unit. Box of Miscellaneous Parts.

2.2 Unloading
2.2.1 Procedures, Cautions, Safety Standards & Weight Data
Extreme care and safety must be exercised in unloading all components. Always use cranes and forklifts of sufficient capacity with chains and cables of recommended design (refer to American National Standards Institute B30.9). The weights of the various elements are indicated on the bill of lading, and on the following diagrams. (CAUTION): EXTREME CARE AND CAUTION MUST BE UTILIZED IN THE UNLOADING PROCESS AS MANY OF THE ELEMENTS ARE TOP HEAVY AND CAN BE PRONE TO TIPPING.

2-1

The Peddimat sub-assemblies include many delicate, precision components. Unloading them requires extreme caution and experience. Peddinghaus Corporation strongly recommends that a professional rigger be employed to unload and place the equipment. (CAUTION): PERSONNEL INVOLVED WITH THE UNLOADING AS WELL AS THOSE IN THE AREA SHOULD WEAR APPROPRIATE SAFETY GLASSES, SAFETY SHOES, HARD HATS AND PROTECTIVE WORK GLOVES.

(WARNING): THREADED HOLES WITH OR WITHOUT LIFTING EYES MAY BE PROVIDED. HOLES ARE PROVIDED IN SOME PLATES THAT ARE OF SUFFICIENT STRENGTH FOR LIFTING THOSE ASSEMBLIES. NEVER USE EYEBOLTS OR THREADED HOLES LOCATED ON CYLINDER ASSEMBLIES OR ELECTRIC MOTORS FOR LIFTING THE ENTIRE ASSEMBLY. THESE EYEBOLTS OR TAPPED HOLES ARE FOR LIFTING ONLY THOSE DEVICES AS INDIVIDUAL COMPONENTS. For components having no holes provided, such as roller transfer module sections, straps may be placed around the main frame members. The following diagrams have data for lifting the various assembly and sub-assemblies of your Peddimat CNC System. These can be used for initial receiving of your system as well as for maintenance of your system.

2-2

MAIN MACHINE STRUCTURE

2-3

MAIN MACHINE STRUCTURE

2-4

STANDARD ROLLER TRANSFER MODULE SECTIONS

2-5

HYDRAULIC POWER UNIT

2-6

NOTE: Dimensions And Weight May Vary If A Different Plasma Unit Is Used. HYPERTHERM HT2000 PLASMA CUTTING SYSTEM

2-7

TORIT MODEL DFT 2-8 FILTRATION SYSTEM

2-8

2.2.2 Machine Set-Up

The various components should be set at the location of final assembly per your general arragement drawing. This drawing will also show the location of optional equipment and specific notes of installation.

(CAUTION): MANY OF THESE UNITS ARE TOP HEAVY AND MAY TIP IF NOT BALANCED PROPERLY. EXERCISE EXTREME CAUTION WHEN POSITIONING THESE SUB-ASSEMBLIES TO THEIR LOCATION AS INDICATED ON YOUR LAYOUT DRAWING.

2.2.3 Dismantling of Packing

Various methods of packing are employed to insure that the shipment arrives at its destination intact. Once this packing material has been removed, all parts and components should be verified with the packing list. A list indicating shortages must be made immediately.

2.2.4 Cleaning
A protective coating has been applied to various machine surfaces to eliminate corrosion during shipment. A soft cloth should be used to remove this protective coating, where applicable, prior to the arrival of the Peddinghaus service technician.

2.2.5 Hydraulic Power Unit

(CAUTION): THIS PEDDIMAT CNC SYSTEM IS DESIGNED FOR PETROLEUM BASED HYDRAULIC FLUID WHICH IS FLAMMABLE. CHECK APPLICABLE FIRE CODES FOR SPECIAL CAUTIONS. The hydraulic reservoir will be shipped empty. Refer to the hydraulic maintenance section (section 7.4) for filling instructions. The reservoir holds 120 gallons (454 liters). The visual sight gauge should be used to confirm that the reservoir is at the proper level. The minimum start-up temperature of the hydraulic power unit is about 55 F (13C). In cold temperatures, be certain to bring oil temperature up by running the power unit prior to machine start-up.

2-9

2.2.6 Optional Equipment

Optional equipment should be set at the location of final assembly per your general arrangement drawing. Additional equiment which may have been purchased will have individual mechanical maintenance manuals for each. These manuals provide all necessary data for set-up, adjustment and maintaining.

2.3 Machine Connections

2.3.1 Hydraulic Connections
All the various hydraulic connections on your Peddimat CNC system have been made at the factory. The only exception is the hydraulic hose connections to the power unit.

2.3.2 Electrical Connections

Prior to the arrival of the Peddinghaus service technician, suitable electrical leads must be brought into the main electrical enclosure as shown on your Peddinghaus Corporation approval drawing. It is absolutely essential that the leads be of sufficient capacity and the voltage is the same as indicated on your general arrangement drawing. A good earth ground is required to achieve satisfactory operation of CNC systems in an industrial environment. To ensure proper operation of the Plasma System, ensure personal safety, and reduce emission of radio frequency interference, the Plasma System shall be grounded as follows: Connect the machine grounding terminal to a high quality earth ground within 20 feet (6 meters) of the machine. A suitable ground consists of a standard copper coated ground of at least 1/2 inch (13mm) diameter driven to a depth of at least 8 feet (2, 4 meters) into the earth below the permanent moisture level. MAKE SURE ALL CONNECTIONS MAKE GOOD METAL TO METAL CONTACT. Refer to local and state codes for acceptable grounding procedure. The machine grounding terminal is located at the main power disconnect electrical cabinet. Also, see Figure 2.3.2.1. for plasma power unit work-ground-cable to machine mounted terminalblock connecting point location. Refer to the next page.

(WARNING): DO NOT ENERGIZE POWER TO YOUR PEDDIMAT CNC SYSTEM UNTIL THE PEDDINGHAUS SERVICE TECHNICIAN HAS CHECKED THE INSTALLATION.

2-10

2.3.2.1 Plasma-Torch Ground Connections to Machine Frame

2-11

2.3.3 Pneumatic Connections

Refer to your general arrangement drawing for air requirements and connection location.

2.3.4 Filtration Unit Connections

Power Electrical power to the filtration unit fan-motor is supplied by a contactor located in the main power disconnect enclosure. An additional 115V power connection for the filtration unit control circuit is located at terminations provided in the main electrical enclosure on the exit side of the machine. Refer to the electrical interconnection drawings (schematics/wiring diagrams) supplied with the machine for exact locations. Pneumatic The air hose for the filtration systems self-cleaning feature, is to be connected to its own dedicated air supply line & should be regulated/filtered to provide 90-100 psig of clean & dry air. Ref: See your General Arrangement drawing for further details. Flexible Duct See your General Arrangement drawing for equipment locations. The flexible-duct provided is 25ft (7.6 meters) long and includes two (2) clamps required for connecting the duct at each end. Ref: The flexible-duct has a service temperature rating of 550 F (288C) maximum. (NOTE): SEE TORIT INSTALLATION & OPERATION MANUAL FOR ADDITIONAL ASSEMBLY & SET UP INFORMATION. A COPY OF THE MANUAL IS INCLUDED WITH EACH TORIT MODEL DUST COLLECTOR SYSTEM SHIPPED BY TORIT MANUFACTURING CO.

2.3.5 HT2000 Plasma Arc Cutting System Connections

The machine is shipped with the plasma torch-leads already routed and connected to the machinetorch, which comes installed in its normal operating location on the exit side of the machine. For torch-lead connections at the Power Supply, and all other component/hook-ups required to bring the HT2000 Plasma System to fully operational status, see and follow the specified directions per SECTION 4-INSTALLATION in the HT2000 Plasma Arc Cutting System Instruction Manual #802070.

2-12

2.3.5.1 HT 2000 Power Supply Placement

After all torch-leads originating from the FPB have been connected to their respective connections at the rear of the power supply as previously instructed, the power supply is ready for final operating positioning. The selection of the final operating placement of the power supply should include the following criteria: Place the power supply in an area that is free of excessive moisture, has proper ventilation and is relatively clean. Allow room for accessing the sides of power supply for servicing. Place the power supply so that airflow is not blocked in any way. (Cooling air is drawn in through the front panel grating and is exhausted through the rear of the unit by a cooling fan). Do not place any filter device over the air intake locations. This reduces cooling efficiency and VOIDS THE WARRANTY. After placement of the power supply, the line disconnect switch box can be placed close to the power supply for safety purposes.

2.3.5.2

Routing/Re-Routing The Torch Leads

Whenever routing or re-routing of the torch leads is required, the torch leads will usually need to be routed through the power track located on the FPB. Before routing the torch leads, remove the torch from the torch leads. After the torch lead routing/re-routing has been completed, replace the torch; it is now ready to be re-mounted, realigned (if required) and height adjusted as described in the sections of this manual entitled: Torch Position Relative to Axis Adjustments (Pages 1-15) Torch Height Set-Up Data (Pages 1-14)

(CAUTION): DO NOT ROUTE THE TORCH LEADS WITH THE TORCH CONNECTED. DAMAGE TO THE TORCH COULD RESULT FROM DROPPING, BANGING, OR SCRAPING.

2-13

2.4 Requesting Service Technician for System Start-Up

Once the system is unpacked and set up as described previously, it is time to contact Peddinghaus Corporations Service Department to schedule the arrival of their service technician. The Peddinghaus Service Department can be reached at 815-937-3800 during the hours of 8 to 5 central standard time, or by Fax at 815-937-4003.

2-14

SMOKE COLLECTOR FOR PLASMA MACHINES

AIR FLOW ADJUSTMENT

The Dampener adjustment is made by the following technique:
Close the Dampener almost completely [90%]. Burn metal and observe the smoke rising near the Plasma torch. Adjust the Smoke Collectors Dampener to just capture the smoke. The Dampener must be securely locked in place after adjusting. Use a tool to assist locking the Dampener to prevent loosening from vibration. 1] Variations in Smoke Collector Dampener designs might require different Dampener adjustment motions. 2] Do not adjust the Dampener 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 installation to have a unique Dampener Setting. 4] As filters are used seasoned, the amount of Dampening will change. New filters will require a more closed Dampener. Changing from used seasoned to new filters will require an evaluation of whether the Dampener airflow needs to be reduced again.

EXCESSIVE AIRFLOW MAY CAUSE HOT SPARKS TO ENTER THE FILTER MEDIA, OR CAUSE PARTICLES TO BECOME IMBEDDED INTO THE FILTER MEDIA. IMBEDDED PARTICLES WILL PREVENT FILTER SELF CLEANING DURING THE PURGING PROCESS.

2-15

-DANGERDust Collector Application Aluminum & Steel

Peddinhaus Corp. requires a dedicated dust control system for aluminum and another system for the carbon steel material due to the enhanced risk of fire or explosion when mixing these two metals. In addition to the fire risk associated with finely divided aluminum particles, the mixture of aluminum and iron oxide creates an additional complication. This mixture can produce a highly exothermic reaction referred to as a thermite reaction (Fe2O3 + Al) which is very difficult to stop once it starts because the reaction provides its own oxygen and can generate temperatures in excess of 2000F. Because of this hazard and our own interpretation of NFPA 65, which stipulates that dusts from aluminum process should be collected in an independent system we require independent systems for aluminum processing. The customer is the only party who can evaluate and determine the appropriate configuration and installation of dust control equipment. The customer will have to discuss these issues with their internal safety staff and other appropriate authorities such as the fire marshal or their insurance agent to make their decision on appropriate actions.

2-16

3. SYSTEM SPECIFICATIONS
3.1 Specifications
3.1.1 Material Processing Parameters
1. Thickness ALL ALL Widths ALL Minimum: Maximum: 0.125 (3,2 mm) 1 maximum (special circumstances up to 1-1/4 thickconsult Peddinghaus sales staff). 3.00 72.88 60.88 20.88 44.5 42.5 42.5 40.00 ( 75 mm) (1851 mm) includes .88 (22mm) for Mill Tolerance (1546 mm) includes .88 (22mm) for Mill Tolerance ( 530 mm) includes .88 (22mm) for Mill Tolerance (1130mm) (1080mm) (1080mm) (12,2 Meters)

2.

Minimum:

FPB1800/3A Maximum: FPB1500/3C/D/E Maximum: FPB 500/E Maximum: 3. Length FPB1800/3A Minimum: FPB1500/3C/D/E Minimum: FPB500/E Minimum: ALL Maximum

Note: For additional material processing limits, refer to pages 3 - 8 through 3-11 later In this section.

3.1.2 Punching Parameters

Apply to materials having a maximum shear strength of 60,000 psi (414 Mega pascals)

1.

Punching Capacity Rating (Tons): All Punches 177-USA (160 - Metric)

2. 3.

Full Stroke of Press Ram: 2.25 (57.15mm) Triple-Tooling Positioning Range (See LAYOUT, page 3-8) Any punch center-line can be positioned to punch anywhere from edge to edge (inclusive) of the maximum material width.

3-1

4. 5.

Triple-Tooling Absolute Positioning Accuracy: SEE DIAGRAM 3.1.2.1. Triple-Tooling/Plasma Torch Positioning Speed: a. b. c. Material Feed Rate (X-Axis) 850 i.p.m. Max. (21,5 Meters/Min.) Tooling/Plasma Torch (Y-Axis): 850 i.p.m. Max. (21,5 Meters/Min.) Circular Interpolation (X, Y-Axis) 1,200 i.p.m. Max. (30,4 Meters/Min.)

6.

Punch & Die Specifications (Including Die Clearance Data & Punch Tonnage Calculation Formula) See Section 3.1.11.

3-2

3.1.2.1 True-Positioning Punching Accuracy Specs of FPB Machine

3-3

3.1.3 Plasma Torch Material Cutting Parameters

Note: Based on standard (Hypertherm) factory configuration for mild steel cutting; using air for both plasma and shield gases. 1. Thickness: Minimum: Maximum: 0.125 1.250 6.00 (3,2 mm) (31,75 mm) (152,4 mm)

2.

Drop-Off:

3.1.4 HT2000 Plasma Torch Maximum Material Piercing Limit

The HT2000 can pierce metals up to a thickness of (1) inch (25,4 mm) maximum.

3-4

3.1.5 General Layout Showing Various Machine Features & Specs

3.1.5.1 General Layout For FPB1500 & FPB500

3-5

3.1.5.2 General Layout For FPB1800

3-6

3.1.6 Material Processing Limits

3.1.6.1 Minimum Allowable Plate Length

3-7

3.1.6.2 Material Camber Processing Information

3-8

3.1.6.3 Material Bow Limits & Correct Bow Processing Orientation

3-9

3.1.6.4 Bow Induced in Material Due to High-Density Hole Punching

Note: For FPB sales where the primary application will be high density plate perforation (such as is required for heat-exchanger tube mounting plates) or any other applications requiring high density hole processing in plate, Peddinghaus Engineering recommends specific application data be submitted. The amount of bending (bow) induced in a plate due to hole punching, is a function of many variables such as material type, material thickness, hole diameter, and quantity, hole pattern spacing and location, etc.

If required hole density exceeds sketch shown above, Peddinghaus Engineering recommends the

prospective FPB buyer to send in drawings describing their hole density application, to Peddinghaus Corp., for processing feasibility determination.

3-10

3.1.7 Triple-Tooling Punch & Die Specifications

3.1.7.1 Punch Tooling (270 Series)

3-11

3.1.7.2 Additional Punch Tooling (290 Series)

3-12

3.1.8 Changing Punches And Dies

(CAUTION): ALWAYS MAKE CERTAIN ALL MACHINERY COMPONENTS WILL MAINTAIN A SAFE POSITION DURING ALL SET-UP, MAINTENANCE AND REPAIRS BY USING ADEQUATE PHYSICAL BLOCKING, RESTRAINT, AND CONTROL PROCEDURES. NEVER DEPEND UPON THE MACHINES HYDRAULIC OR PNEUMATIC POWER TO HOLD OR MAINTAIN ANY COMPONENTS IN A CONSTANT POSITION. Note: Prior to starting any tooling changes, move the machine y-axis (triple tooling/torch axis) to a position approximately midway between the two vertical hold down wheels on the entry side of the machine. This will create the maximum and most convenient working space to accomplish tooling changes. Shut Down Procedure Before performing any routine tool change on machine, or any associated equipment or options, Be certain to turn off the CONTROL CONSOLES POWER SWITCH, TURN OFF THE MAIN POWER DISCONNECT ON THE HYDRAULIC POWER UNIT, AND PUSH THE E-STOP BUTTON CLOSEST TO THE LOCATION OF THE WORK BEING DONE & FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES BEFORE PROCEEDING. REFER TO SECTION 6.5.1. FOR DETAILS. Changing Punches For removal of punches, use the wrench provided with the machine. Use wrench Part # YB18160017-00-00. NOTICE: There are three (3) Punch Sleeve adapters supplied with each FPB machine which convert the 292 (punch series) Coupling Nut (Part #YD18160-001-00-04) to a 272 (punch series) Coupling Nut (Optional Item/Part #YD18160-001-00-09). The Punch Sleeve adapter is Part #YD18160-001-00-07. Changing Dies For removal of dies, proceed as follows: Loosen and back-out the die holding set-screws far enough to permit Die removal and changeover. (See Figures 3.1.9.1 or 3.1.9.2 on previous pages for set-screw locations). A 3/16 hex key wrench is required for the set screws.

3-13

To install/re-install the desired die(s), place die(s) into the desired removable die pocket(s) and tighten set-screw(s) securely. BE SURE ALL SCREWS ARE TIGHTENED PROPERLY BEFORE RESTORING POWER TO THE MACHINE. Notice that there are two (2) different size removable die pockets for this machine: 1. 2. Removable Die Pocket for 271 series dies. Part #: YC18160-004-00-18 Removable Die Pocket for 291 series dies. Part #: YC18160-004-00-14.

These die pockets may be used in any combination and at any die station desired, with their corresponding punch and die sets, since all stations have same tonnage rating. There is an optional Die Holder Clamp Bar available for this machine, which simultaneously clamps/unclamps all three (3) removable die pockets at once instead of individually as when using the standard Clamp Blocks supplied. This may be quicker and/or more convenient for certain punching applications. The part # for this optional Die Holder Clamp Bar is: YC18161017-00-02.

(CAUTION): BE SURE TO ADHERE TO ALL SAFETY PRECAUTIONS AND STANDARDS SPECIFIED WHENEVER TOOLING CHANGES ARE UNDERTAKEN!

3-14

3.1.9 Punch And Die Specifications (for FPB)

The information below is based on using the following punches and dies on the FPB machine. The machine is capable of 177 tons on any of the punch stations. It uses the #272, #282 or #292 punch styles and the #271 or #291 dies. It can not use the #281 style dies. NOTE: The punch ram always has a keyway, therefore there is never a time when the punch head has full area contact with the punch ram. If a punch without a key is used, it is exactly the same as using a punch with (1) key. Maximum Tonnage For #272 Punch (1-1/4 Maximum Hole Size) Maximum Tonnage For #271 Die Maximum Tonnage For #282 Punch (1-1/2 Maximum Hole Size) Maximum Tonnage for #281 Die Maximum Tonnage for #292 Punch (1-3/4 Maximum Hole Size) Maximum Tonnage For #291 Die with (1) Key with (2) Keys 130 Tons 100 Tons

(1-9/16 Max Hole) 177 Tons (1-5/16 Max Hole when used on FPB) with (1) Key with (2) Keys CAN NOT BE USED with (1) Key with (2) Keys (1-27/32 Max. Hole) 234 Tons (177 Max on FPB) 194 Tons (177 Max on FPB) 182 Tons (177 Max on FPB) 170 Tons 138 Tons

3.1.9.1 Recommended Die Clearance:

(10% Of Material Thickness) Approximate Values: Up to 1/4 (6mm) Thick = 1/32 (0,75mm) Above 1/4 (6mm) To 3/4 (20mm) Thick = 1/16 (1,5mm) Above 3/4 (20mm) Thick = 3/32 (2,25mm)

3.1.9.2 Formula For Punch Tonnage:

Punch Perimeter (In Inches) X Thickness (In Inches) X 65,000 psi (Ultimate Shear Strength In p.s.i.) /2,000 LBS. = Punch Tonnage

3.1.9.3 Punches And Dies Supplied With FPB

(2) 13/16 Round #272 Punches (1) 1-3/4 Round #292 Punch (2) 7/8 Round #271 Dies (1) 1-13/16 Round #291 Die

3-15

3.1.10 Plasma-Torch Adjustable Stand-Off Height Specifications

The settings specified in the sketch below are for the plasma-torch cutting of material (plate) ranging in thickness from 3/16 (5mm) to 1-1/4 (32mm).

3-16

3.2 Torit Model DFT 2-8 Filtration System Specifications

The Torit model DFT 2-8 is a self-contained, high efficiency, continuous cleaning, cartridge type filtration system.

3.2.1 Filters, Accessibility and Cleaning

Filters Quantity & Type: (8) Cartridge type filter elements Filter Cartridge Dimensions: 13.84 outside dia. x 26 long (352mm x 660mm) Filter Media Data: * * * * Actual total filter area: 1,584 sq. ft. (147 sq. meters) Type: Pleated Polyester Maximum operating temperature: 275 F (135 C) Replacement element part number: 8PP-46930-00 (Ref. Peddinghaus Part #YD2308041)

Accessibility Four (4) filter access covers are provided to gain access (for replacement, observation, etc.) to the filter cartridges from outside the unit. Cleaning The filter cartridge elements are automatically and continuously cleaned in successive banks of (2) filters at a time. Four (4) solenoid valves introduce jets of dry air into each filter cartridge via a venturi opening with the resulting air blast cleaning the element. A remotely mounted and adjustable solid state timer controls the cycle time. Compressed Air Requirements * Unit requires 90-100 psig (620-690 kilopascals) of clean and dry air at a consumption rate of approximately 18 standard cubic ft/min. (255 liter/min.) with 5 second pulse interval setting. Dew Point (for outdoor installations) should be -40 F (-40 C).

Cycle Time Adjustment Data * * Pulse time on: 100 milliseconds (.05 to .10 recommended) Pulse time off: Adjustable ranges are as follows: 1 - 1.5 seconds minimum, 60 66 seconds maximum. Set at Peddinghaus to 5 seconds.

3-17

3.2.2 Filtration System Capacity, Performance & Construction Data

3.2.2.1 Filtration System Capacity
Filtration system will exhaust 1500 cubic ft./min. (42,3 cubic meter/min.) with an available external static pressure of 6.0 inches water gauge (1,5 kilopascals) with a normal operating pressure drop of 4.0 inches water gauge (1,00 kilopascals). A magnahelic gauge is provided to monitor filter pressure drop.

3.2.2.2 Filtration System Effiency

The system efficiency is 99.9%+ on one (1) micron size particulate and larger. Unit is acceptable where local codes permit and where TLV values are in acceptable range, based on the above efficiency.

3.2.2.3 Filtration System Blower Package

Description of Standard Model: (Peddinghaus Part #: YD2308040) System comes supplied with a Baldwin Power TEFC Direct Drive Blower with 5 H.P., TEFC, 230/460 Volt, 3-Phase, 60Hz motor ...mounted on top of cabinet and furnished with an Outlet Flow Damper. Description of Optional Model : (Peddinghaus Part #YD2308047) System comes supplied with a Baldwin Power TEFC Direct Drive Blower with 5 H.P., TEFC, 575 Volt, 3-Phase, 60Hz motor....mounted on top of cabinet and furnished with an Outlet Flow Damper. Typical Blower Package Performance: 1500 cubic feet/minute (CFM) (42 cubic meter/min) at 10 water gauge (2,5 kilopascals) Static Pressure at 4.0 Brake Horse Power.

3.2.2.4 Filtration Unit Construction

The unit is constructed of 12 gauge steel, both plenum chamber and cabinet. The unit has sealed seams and gasketed filter access covers and fittings for air-tight integrity.

3.2.2.5 Particulate Discharge Hopper

A 60 sloped-side hopper, terminating to a square outlet, makes up the bottom section of the filtration unit housing. Hopper inlet size: 7(178mm) outside diameter tube.

3-18

Hopper outlet size: 18 (457mm) square Accessory: Gasketed-Drum-Lid-Kit which attaches to 18 (457mm) square discharge end of hopper and the other end terminates with a gasketed-drum-lid for use with a standard 55 gallon (208 liter) drum. The drum is NOT supplied.

3.2.2.6 Filtration System Paint Specifications

The unit is painted, internally and externally, with 1.5 mil. thickness of Ti-Kromatic blue, making the unit suitable for outdoor installation.

3.2.3 Filtration System Shipping/Additional Information

A. Shipping Data Components: The filter unit is shipped with 5HP power pack (blower unit) installed on top. The filter cartridges are factory installed. The legs, 55 gallon Drum-Lid-Kit and any accessories are shipped in separate box included within the shipping crate. Weight: Shipping weight is approximately 1800 pounds (817 kg.) Assembled Dimensions: Overall Height: Overall Width: Overall Length: 12 ft. - 4 in. 3 ft. - 4-1/4 in. 7 ft. - 1-1/4 in. (3,76 Meter) (1,02 Meter) (2,17 Meter)

3-19

B.

Additional Data 120 Vac 50-60 Hz Zone 3 100 mph (161 km/hr) +20 in. water (+5 kilopascals) 4 Approximately 18 cubic feet/min. (510 liter/min.) (at 5 second pulse interval) 90-100 psig (6,2-6,9 bar) Blue (Std.)

Remote Mounted Timer Seismic Rating Wind Load Rating Housing Rating Number of Valves (for cleaning) Air Consumption Compressed Air Required Standard Paint Finish

3.2.4 Filter Cartridge Monitoring/Maintenance

Refer to Care & Maintenance of Original Equipment Mfg. Devices section, pages 7-31 and 7-32 for filter monitoring and changing directions.

3-20

4. System Assembly I.D.S

4.1 General Arrangement of Standard Equipment

4-1

4.1.1 FPB System Component Size & Weight Data Sheet

4.1.1.1 Approximate Machine Size
(Does NOT Include: Plasma Power Unit; Filtration System; Hydraulic Power Unit; & Roller Transfer Modules) Overall Dimensions: FPB 1800/3A FPB 1500/3/C/D FPB 500/3E Width 204 (5182mm) 180 (4572mm) 140 (13556mm) x Depth 98 (2489mm) 96 (2438mm) 96 (2438mm) x Height 108 (2744mm) 108 (2744mm) 108 (2744mm)

4.1.1.2 Approximate Machine Weight;

(Does NOT Include: Plasma Power Unit; Filtration system; Hydraulic Power Unit; & Roller Transfer Modules) FPB 1800/3A FPB 1500/3C/D FPB 500/E 34,000 Pounds (15450 Kilograms) 28,000 Pounds (12712 Kilograms) 20,000 Pounds ( 9072 Kilograms)

4.1.1.3 Approximate Component Dimensions and Weight

COMPONENT

W
HT2000 Plasma Power Unit Torit DFT2-8 Filtration Unit Hydraulic Power Unit 28.25 (718mm) 40 1/4 (1022mm) 60.00 (1524mm)

SIZE D
41.25 (1048mm) 85 1/4 (2166mm) 38.00 (965mm)

WEIGHT

H
35.5 (902mm) 148.00 (3760mm) 48.00 (1219mm)

(Metric)
780 Pounds (354 Kg) 1,800 Pounds (817Kg) 1,000 Pounds *(454 Kg)

*Without Hydraulic Oil in Reservoir....Weight Full (with 120 gallons oil in Reservoir)= 2,000 lbs. (910kg)

4.1.1.4 Maximum Hydraulic Pressure

2,750 PSI (19 MPa)

4-2

4.1.2 Material Path Through FPB & Various Component I.D.s

4-3

4.2 Emergency Off Buttons & Safety Switches

(CAUTION): ALL OPERATORS AND PERSONNEL IN THE GENERAL AREA OF THE MACHINE MUST BE FAMILIAR WITH THE LOCATION AND OPERATION OF ALL EMERGENCY OFF BUTTONS.

PAGE 1 OF 4

4-4

4.2 Emergency Off Buttons & Safety Switches (Contd.)

PAGE 2 OF 4
4-5

4.2

Emergency Off Buttons & Safety Switches (Contd.)

PAGE 3 OF 4

4-6

4.2 Emergency Off Buttons & Safety Switches (Contd.)

PAGE 4 OF 4
4-7

4.2.1 Fiber Optic Sender/Receiver Operational Information

The fiber optic sender/receiver safety-interlock switches are precisely located in the triple-tooling housing so that all punch blocks must be either fully extended or fully retracted (depending on tool selection criteria) in order for a punch cycle to be allowed to occur. This punch operation safety-interlock feature was designed into the machine to prevent the tooling from destroying itself.

4-8

5. Control Switches
All of the following switches are pre-set at Peddinghaus for the proper operation of this machine. Should any switch need re-adjusting, follow this guide, and ALWAYS FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES BEFORE PROCEEDING.

5.1 Y-Axis Switches

5-1

5.2 X - Axis Material Leading - Edge Reference Switch

5-2

5.3 Punch Cylinder Control Switches

5-3

5.4 Opposite Datum (Fiber Optic) Control Switch Config.

5-4

6. SAFETY FOR PEDDIMAT SYSTEMS

6.1 Training
This Safety chapter is provided by Peddinghaus Corporation to assist users of Peddimat CNC systems in training of personnel in the safe operation and servicing of these systems. Such training is essential to promoting personnel awareness of potential hazards involved in negligent operation or in improper use, or abuse, of the system or its components. When language or illiteracy would not permit any person to read or understand this manual, it will be the employers responsibility to translate/interpret as required to the appropriate persons for their complete understanding. Training of personnel should assure their complete understanding of: Maximum and minimum capacities and capabilities. Proper set-up of each machine, including understanding of program software. Function and location of all operating control devices and all operating modes. Locations of all emergency stop controls (push buttons, cables, panic bars, etc.) Safe operating procedures for the system. Safety precautions for servicing machines or the system, applicable standards, regulations and codes. Plant safety rules and practices, including the use of personal protection equipment provided by the employer.

Effective training of personnel requires: Testing to determine the level of competence achieved. Periodic retraining and updating to assure continuing awareness by personnel of potential hazards.

To assure awareness by personnel involved in the initial start-up, run-in and hazard investigation, training should begin prior to installation of the system. Training should be by personnel who are themselves properly trained in the use of a Peddimat CNC system, and who are experienced in fabricating shop practice. Statistics have shown that accidents can occur as a result of improper training by personnel who are inadequately familiar with safe work practices. This Safety Manual should be made readily available to all personnel involved in the operation or servicing of Peddimat CNC systems; it will serve no useful purpose in a filing cabinet or on a
6-1

library shelf. If additional copies are required for proper dissemination of the information, please advise Peddinghaus Corporation. IMPORTANT! ONLY PERSONNEL WHO THOROUGHLY UNDERSTAND THE CONTENTS OF THIS SAFETY MANUAL SHOULD BE ASSIGNED TO THE SUPERVISION, OPERATION OR SERVICING OF A PEDDIMAT CNC SYSTEM.

6.2 Safeguarding Peddimat Systems

Peddimat Structural Steel Fabricating Systems are complete manufacturing systems which incorporate individual cells (work stations) for performing all operations required for the particular product to be produced. Each cell includes a machine for performing a specific operation. The individual cells are integrated with transfer modules to move the part automatically into programmed positions. The arrangements of individual cells and transfer units are provided in accordance with a user specified plant equipment layout. The Peddimat CNC system has eliminated most manual operations and has greatly reduced crane and lift truck handling of heavy structural steel members, thereby eliminating many of the inherent hazards involved in traditional structural steel fabrication processes. These processes can now be completed without manual intervention except for set-up and service functions. However, without appropriate safeguarding means, personnel exposure to potential hazards may be possible. The Occupational Safety and Health Act assigns solely to the employer the responsibility for providing a safe place of employment. Employer responsibilities under this Act will be found in Title 29, Code of Federal Regulations 1910. Sections which may have specific application to a Peddimat system include the following: 1910.5 1910.24 1910.27 1910.37 Application of standards Fixed industrial stairs Fixed ladders Means of egress, general

1910.144 Safety color codes for marking physical hazards 1910.145 Specifications for accident prevention signs and tags 1910.147 Control of hazardous energy (lockout/tagout) 1910.212 General requirements for all machines 1910.219 Mechanical power transmission equipment 1910.252 Welding, cutting, and brazing

6-2

Based on the current state of the art, Peddinghaus Corporation has designed individual machines and components of Peddimat CNC systems to either eliminate hazards or to provide appropriate safeguarding against recognized hazards. However, providing safeguarding of the completed system cannot be effectively accomplished until the system has been installed in its final location, and hazard identification has been completed for the system by personnel familiar with the manufacturing processes to be implemented. This must be considered the primary responsibility of the users of the system. Peddinghaus Corporation and its personnel have extensive experience in fabrication, machinery design and construction. We have also acquired considerable general knowledge of fabricating processes from working closely with users of our machines: however, we lack detailed knowledge, experience or control in the following: Your plant layout Your product design and manufacturing processes Training and experience of your personnel Level and frequency of your supervision State and local codes and regulations Union contracts (work rules and trade lines) Your plant safety rules and procedures

Accordingly, decisions regarding hazard identification and hazard control strategy must be made by user personnel with knowledge and experience in these areas. We recommend that each Peddimat user acquire copies of the following safety standards for use as technical references and guidance in the process of hazard identification and the planning of hazard control strategies, as well as in planning an overall safety program: ANSI B11.4-1983 Safety Requirements for Shears ANSI B11.5-1988 Safety Requirements for Iron Workers ANSI-B11.7-1983 Safety Requirements for Drilling Machines ANSI-B11.10-1982 Safety Requirements for Metal Sawing Machines ANSI Z229.1-1982 Safety Requirements for Fabricating Shops ANSI/ASME B20.1-1987 ANSI/NFPA 79-1987 ANSI/ASC Z49.1-1988 Safety Standard for Conveyors Electrical Standard for Industrial Equipment Safety in Welding and Cutting

6-3

ANSI/AWS C5.2-1983

Plasma Arc Cutting - Recommended Practice For

6.3 Hazard Identification

The process of hazard identification should include a complete review of the system with reference to the following: Potential exposure to foreseeable hazards by production personnel (operators and helpers), service personnel (maintenance, materials, custodial, etc.), and supervisory personnel. Reasonably foreseeable misuse and/or abuse. Inadvertent actions by authorized personnel. Intrusions into hazardous zones by unauthorized personnel. Potential hazard zones include: * Access openings and transfer points between transfer modules; personnel must be prevented from entering these areas unless movement of structural members is prevented. Standing on, or walking along or over, transfer modules or the parts being transferred thereon. Safe means of crossover must be provided for personnel who have a necessity to do so during service operations.

6.4 Hazard Control Strategy

The hazard control strategy adopted by the user will depend upon the nature of the potential hazard identified, the probability of exposure, and evaluation of the potential for severe injury. The hazard control strategy selected can range from awareness devices to physical barriers; options include but are not limited to the following: Safeguarding at the perimeter: The perimeter of Peddimat systems should be clearly defined or marked to prevent personnel from inadvertently entering the area. Unless there are potential hazards at the perimeter, awareness devices may achieve this purpose. Safeguarding within the system: Exposure to potential hazards between individual system elements should be prevented by providing awareness devices or safeguarding means commensurate with the nature of the hazard.

6-4

Safeguarding at individual machines or transfer modules: The safeguarding means provided with the Peddimat system should be reviewed to ensure that the means provided is suitable to the environment into which the system has been installed. Where required, supplemental safeguarding should be provided as changes in working conditions and production demands may deem necessary. Safeguarding during service (set-up, maintenance, etc.): Proper employee training is required to ensure hazard awareness of all service personnel. The most important safeguarding procedure for service personnel is strict adherence to formal procedures for shutting off and locking out all sources of energy before entering hazard zones. Training in proper lockout/tagout procedures is essential to preventing exposure to hazards by service personnel. Applicable means of safeguarding Peddimat systems include: Physical barriers (guards) Presence sensing devices (non-contact barriers) Control systems Operating Procedures

Applicable awareness devices include: Guard rails, chains, ropes, etc. Color coding (floor marking) Signs and/or symbols (if understood by user population) Alarms (suitable for the plant environment)

IMPORTANT! THE HAZARD CONTROL STRATEGY SHOULD ASSURE THAT, IF PERSONNEL ARE ALLOWED TO BE WITHIN THE PERIMETER OF THE SYSTEM DURING OPERATION, SAFEGUARDING MEANS HAVE BEEN PROVIDED AGAINST EXPOSURE TO ANY POTENTIAL HAZARD. IF NOT, THEN PERIMETER SAFEGUARDING SHOULD PREVENT ENTRY OF ALL PERSONNEL WHILE THE SYSTEM IS IN OPERATION.

6.5 Supervision
IMPORTANT! ONLY PERSONNEL WHO THOROUGHLY UNDERSTAND THE CONTENTS OF THIS SAFETY MANUAL SHOULD BE PERMITTED TO SUPERVISE THE OPERATION OR SERVICING OF A PEDDIMAT CNC SYSTEM.

6-5

During initial start-up and run-in of a new system, close supervision is important to ensure that newly trained employees fully understand the equipment, their function in its operation, and the purpose and function of the safe-guarding means provided for their protection. Statistics have shown that industrial accidents usually involve employees newly assigned to a job, or employees experienced in a job assignment who become used to the potential hazards involved. Probably the most important of all considerations is the necessity to continually monitor operations of manufacturing systems to ensure, on a daily basis, that the safeguarding strategy adopted continues in effect for the life of the system. Supervision should constantly ensure that all safeguarding means provided are in place, properly used, and fully understood by all personnel. Preventing an accident is as important twenty-five years after installation as it was during start-up of the new installation.

6.5.1 Lockout/Tagout Procedure

Before performing any service (tool changes, maintenance inspections, repair procedures, cleaning, etc.) involving any element of the Peddimat system, all sources of power (electrical, pneumatic, hydraulic, etc.) must be shut off and locked out. (Refer to CFR 1910.147 Control of hazardous energy). To assure protection against exposure to potential hazards, each individual must be responsible for locking and tagging out energy sources with his or her own personal lock. The following is a recommended sequence: Shut off the electrical power to the machine or system using the normal stopping means on the operators panel, usually the motor Stop push-button. Open the disconnect switch on the main panel by moving the handle or lever to Off position. Lockout and tagout the electrical disconnect switch to prevent inadvertent or accidental restarting of the machine or system. This procedure should be accomplished by yourself. DO NOT rely on others to perform this operation. Once this is completed, try to re-start the machine to confirm that all electrical power is OFF. Exhaust, vent, lockout and tagout hydraulic and pneumatic pressure that is stored. This trapped energy could cause dangerous, unwanted machinery motion.

6-6

6.5.2 General Safety Precautions

(WARNING) FAILURE TO COMPLY WITH ANY ONE OF THE FOLLOWING SAFETY PRECAUTIONS CAN CAUSE SERIOUS INJURY OR EVEN DEATH TO YOURSELF OR OTHERS. AS PREVIOUSLY STATED, IT IS ABSOLUTELY NECESSARY THAT PERSONS INVOLVED WITH PEDDIMAT SYSTEMS THOROUGHLY UNDERSTAND AND COMPLY WITH ALL OF THE FOLLOWING SAFETY PRECAUTIONS. IT IS OF PARAMOUNT IMPORTANCE THAT THE ENTIRE MANUAL BE READ AND COMPLETELY UNDERSTOOD BEFORE THE SYSTEM IS PUT INTO OPERATION OR ANY MAINTENANCE IS PERFORMED.

Never operate the Peddimat system unless you have received proper training and are totally familiar with this manual. Never permit any part of your or anyone elses body to come near the point of operation when the machine is under power. Become fully familiar with the function and location of all emergency stop devices prior to operation of the Peddimat system. Make sure your eyes are always protected with approved safety glasses. Before caring for this machine, read and comply with all safety warnings. The Peddimat system is remotely operated and will start automatically. Always maintain a safe distance between the system as well as the material which is entering and exiting the line. Never bypass or eliminate any safety devices, features or procedures. Never leave the operator control station even if just for a few moments without first depressing the Cycle Stop button. Only use the Peddinghaus provided Peddimat Software Program for generating part programs for the Peddimat system. Furthermore, do not attempt to manually alter the machine tool program that has been prepared by the Peddimat Software. Always make sure that if you are to come in contact with any portion of the Peddimat system, that your hands are protected with snug-fitting hand protection. Never change drill bits or perform any adjustment or maintenance procedures without using the lockout/tagout safety procedure as previously described. Make sure that the routine maintenance schedule as specified in the maintenance chapter is followed. If the system is due for maintenance, operation should cease. System resumption should only occur when the specified maintenance has been performed.

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Never stand, walk along, over or through any part of the transfer modules. Never have more than one piece part on or in the Peddimat system input or output transfer devices at any one time.

Never initiate work procedures that are not endorsed by this manual. If a situation with which you are unfamiliar arises, contact your supervisor (who is trained in the operation of the Peddimat system) for guidance. Never wear jewelry or clothing that could be caught on part of the system and cause you to be pulled into the equipment. Remain alert at all times. Complacency or lack of respect for the systems functions can lead to unsafe acts. Never check a hole or a layout mark location in a piece part that is in the system without first employing proper lockout/tagout procedures. Always maintain proper lighting environment in your work area to eliminate eye strain or fatigue. If you receive any cuts, bruises or injuries (regardless of how minor) they should be reported immediately to your medical department. They are in the best position to judge the seriousness of your injury. Prior to putting the Peddimat system in operation whether it is at the beginning of the shift or after a break, confirm the functionality of all Emergency Stop buttons and Safety Mats. If any devices does not function properly, cease operation until proper function is restored. When performing maintenance, always make sure that all moveable assemblies such as punch and drill heads are blocked by using adequate blocking, restraining or controlling procedures. Never depend on any hydraulic or pneumatic counter balance of Peddimat system to maintain any element in a fixed location. Your Peddimat system employs various hydraulic, pneumatic and electrical circuits. Only individuals thoroughly familiar with these circuits should be permitted to perform trouble shooting. If more than one individual is performing maintenance, cleaning or trouble shooting, each person should use a separate lockout/tagout device. Never attempt to remove punch slugs from the piece part or system while the system is operational and under power. Prior to setting the drill feed rates, check with the Machinerys Handbook published by Industrial Press, Inc. for proper drill feeds based upon the material you are to process. Never operate the system if you or anyone in the area is under the influence of alcohol or drugs.

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Make sure that the illuminated machine operation light is fully functional when power is put to the Peddimat system. If this device does not function, it should be reported to maintenance immediately and operation of the system should cease until the device is made operational. Never use anything except genuine Peddinghaus replacement parts when required. Failure to do so can cause unreliable, unsatisfactory or even unsafe performance. Be sure you are totally familiar with the maximum and minimum capabilities of the Peddimat system as indicated in this manual. Be fully familiar with the operating modes and safeguarding. Make sure no one is on, under, or attempting to cross over the Peddimat System and/or transfer modules. Keep your work area clean and orderly. Make sure all persons are clear of the system before operating.

(CAUTION) FAILURE TO FOLLOW THE SAFE OPERATING FEATURES DESCRIBED ABOVE MAY RESULT IN SERIOUS INJURY OR DEATH TO YOU OR ANYONE IN THE AREA. THE ABOVE DESCRIBED SAFETY PRECAUTIONS ARE DESIGNED TO WARN USERS OF MANY POTENTIAL HAZARDS. IT IS IMPOSSIBLE TO FORESEE ALL THE POSSIBLE USES OR MISUSES OF THE SYSTEM, THEREFORE, YOUR BEST PROTECTION IS TO THINK SAFETY AT ALL TIMES. IF AT ANY TIME YOU HAVE ANY QUESTIONS PERTAINING TO THE SAFE OPERATION OF THIS SYSTEM, DIRECT THEM TOWARD YOUR IMMEDIATE SUPERVISOR OR AS AN ALTERNATIVE, FAX PEDDINGHAUS CORPORATION, ENGINEERING DEPARTMENT AT (815-937-5681).

Various safety signs have been attached to the Peddimat and Transfer Module Systems. These warning signs are not intended to be a substitute for reading and understanding this manual. Warning signs have been located at various points on the system for the most efficient use. They are an integral part of the system and MUST NOT be removed, destroyed, covered or altered. If any of these signs are damaged or removed, the system should not be operational until signs are replaced. Replacements can be procured by contacting Peddinghaus Corporation, 300 N. Washington Avenue, Bradley, Illinois 60915, FAX (815-937-4003).

6.6 Operation

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IMPORTANT! ONLY PERSONNEL WHO THOROUGHLY UNDERSTAND THE CONTENTS OF THIS SAFETY MANUAL SHOULD BE PERMITTED TO OPERATE A PEDDIMAT CNC SYSTEM. The Peddimat CNC system is remotely operated by a single operator located at the operators control station (console). After initiation by the operator, the system will automatically commence performing the sequence of operations that have been programmed for the particular product being processed. IMPORTANT: USE ONLY PEDDINGHAUS PROVIDED SOFTWARE PROGRAMS; NEVER ATTEMPT TO MANUALLY ALTER A MACHINE TOOL PROGRAM THAT HAS BEEN GENERATED BY THE PEDDIMAT SOFTWARE. Placement of the operators control station (console) should permit the operator to maintain surveillance of the points of operation of the various cells that compromise the system. However, no control location can permit operator surveillance of the entire system area at all times. These facts have to be considered when planning the hazard control strategy. The operator should never leave the operators control station (console) until the system has been placed in feedhold: If the system is being taken out of production, the power should be shut off. If the system is to be serviced (tool changes, maintenance procedures, etc.) the lockout/tagout procedure should be followed by each individual assigned to the task to be performed. If the system is to be temporarily shut down to permit the operator to perform a manual task (tool adjustments, cleaning chips, tool or part inspection, etc.) all machine and part movement shall be temporarily stopped: * The Cycle Stop push button will perform a programmed stop of the system when the program block in process has been completed. * The Feed Hold push button will stop the programmed movement of parts being moved on transfer modules. The complete function of these and all other controls are explained in the Operation Section; these functions must be clearly understood by the system operator and all other personnel assigned to work on the system.

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If the system has to be immediately stopped because of an emergency, or because personnel exposure to a potential hazard has been detected, and Emergency Stop push button must be depressed. Emergency Stop push buttons are provided at the operators control station (console) and at strategic locations throughout the Peddimat CNC system. See the Operation Section for specific information about your system.

Recommended practices to be followed by the system operator include the following: Make sure all personnel are beyond the system perimeter before initiating system operation. Stop the system if any unauthorized individual is observed to be within the system perimeter. Do not operate the system with more than one part on a transfer module. Do not remove safety mats or other safeguarding means provided. Do not defeat or by-pass interlocks provided.

6.7 Maintenance (Safety)

IMPORTANT! ONLY PERSONNEL WHO THOROUGHLY UNDERSTAND THE CONTENTS OF THIS SAFETY MANUAL SHOULD BE PERMITTED TO SERVICE A PEDDIMAT CNC SYSTEM. All system maintenance personnel should be trained using this Operator Manual and the company lockout/tagout procedure. This manual should be accessible to all system maintenance personnel at all times. IMPORTANT! NO SERVICE WORK SHOULD BE ATTEMPTED UNTIL ALL ENERGY SOURCES TO THE SYSTEM HAVE BEEN SHUT OFF USING THE LOCKOUT/TAGOUT PROCEDURE. Follow the routine maintenance schedule provided in the maintenance section. Maintenance inspections should not be contacted until all energy sources to the system have been shut off using the lockout/tagout procedure.

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6.8 Set-Up And Tool Changing

IMPORTANT! ONLY PERSONNEL WHO THOROUGHLY UNDERSTAND THE CONTENTS OF THIS OPERATORS MANUAL SHOULD BE PERMITTED TO SET-UP A PEDDIMAT CNC SYSTEM, OR TO CHANGE TOOLING DURING PROGRAMMED STOPS OR BETWEEN SET-UPS. All system set-up personnel should be trained using this Operator Manual and their employers lockout/tagout procedure. This manual should be accessible to all system set-up personnel at all times.

6.9 Warning Signs

Employer responsibilities for warning signs will be found in Title 29, CFR 1910.145 (Specifications for accident prevention signs) and Title 29, CFR 1910.144 (Safety color codes for marking physical hazards). Various warning signs have been attached by Peddinghaus Corporation to portions of the Peddimat CNC system to make users aware of potential hazards for which safeguarding means should be provided after the system has been installed. IMPORTANT! WARNING SIGNS ARE NOT SAFEGUARDING DEVICES; THEY CANNOT BE RELIED UPON TO PROTECT PERSONNEL FROM EXPOSURE TO POTENTIAL HAZARDS. PEDDINGHAUS HAS PROVIDED CERTAIN WARNING SIGNS TO PROVIDE AWARENESS TO PERSONNEL OF SPECIFIC POTENTIAL HAZARD ZONES IN THE ORIGINAL INSTALLATION, SUCH AS TRANSFER POINTS BETWEEN TRANSFER MODULES. THIS DOES NOT REMOVE THE EMPLOYERS RESPONSIBILITY TO RESTRICT ACCESS OR TO PROVIDE SAFEGUARDING MEANS FOR SUCH POTENTIAL HAZARD ZONES, AS REQUIRED BY TITLE 29, CFR 1910.212 (GENERAL REQUIREMENTS FOR ALL MACHINES). If additional warning signs are deemed to be necessary to suit the specific plant layout for the Peddimat installation, a wide variety of standard warning signs are available from safety equipment suppliers. Peddinghaus Corporation will be pleased to provide upon request additional signs of Peddinghaus design.

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IMPORTANT! IF A PEDDIMAT SYSTEM LAYOUTS CHANGED BY PLANT REARRANGEMENT OR BY ADDITION OF TRANSFER MODULES OR WORK STATIONS, A NEW HAZARD IDENTIFICATION PROCESS WILL BE NECESSARY TO DETERMINE IF NEW POTENTIAL HAZARD ZONES HAVE BEEN CREATED, AND TO ESTABLISH THE APPROPRIATE HAZARD CONTROL STRATEGY TO SAFEGUARD SUCH HAZARDS.

IMPORTANT! THE ABOVE ARE GENERAL SAFETY PRECAUTIONS APPLICABLE TO PEDDIMAT CNC SYSTEMS. FAILURE TO OBSERVE ANY OF THESE PRECAUTIONS MAY RESULT IN PERSONNEL EXPOSURE TO A HAZARD. SOME APPLICATIONS MAY INTRODUCE OTHER HAZARDS WHICH ARE NOT FORESEEABLE TO PEDDINGHAUS CORPORATION, BUT FOR WHICH SAFEGUARDING MEANS OR SAFE OPERATING PROCEDURES WILL HAVE TO BE DEVELOPED.

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SAFETY GUIDELINES
SET UP
Is point of operation safeguarding properly installed? Test all required operation control stations, Emergency Stop Buttons, Safety Mats, modes of operation and safeguarding prior to set up. Instruct operators in the proper use of set up procedures. Check, with power off, that all tooling is properly installed and fits properly.

OPERATION Always use point of operation guarding. Know the set up and proper method of operation. Test all required operator control stations, Emergency Stop Buttons, Safety Mats and modes of operation before each shift, each job and after each break. Keep all body parts out of point of operation area. Do not position any part of your body where it can be struck or crushed by a piece part or machine movement. Make sure everyone is clear of the Peddimat system before operating. Turn off all power to the Peddimat when not in operation. It is essential that the operator be fully aware of his responsibilities.

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SAFETY MAINTENANCE CHECK

Is safeguarding at the point of operation in proper adjustment and in proper operational condition? Is pinch point guarding properly installed? Are all safety interlocks and emergency stop switches functioning properly? Are all operating modes functioning properly? Are all warning signs clean, easily understandable and in place? Are all auxiliary transfer devices checked and working properly? Is the safety manual and operator manual attached to the machine? Has scheduled normal maintenance been completed?

SAFETY AND SAFETY AWARENESS IS A FULL TIME RESPONSIBILITY. THE MORE ATTENTION YOU PAY TO SAFETY, THE LESS CHANCE OF INJURY TO YOU AND OTHERS.

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DANGER
To reduce the possibility of injury: DO NOT Position any part of your body in a location where it can be pinched or crushed. ALWAYS Read and understand the Operation Manual before performing any maintenance or operation to this Peddimat system.

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7.
7.1

CARE AND MAINTENANCE

Lubrication

The primary lubricants used on this Peddimat PC/CNC system are as follows; Pure lithium grease applied by grease gun. MOLYCOTE BR2 GREASE applied by grease gun, brush, or hand packed. (Moly-disulfide paste grease). SAE 30 OIL or equal applied by spout can. ISO GRADE 100 (ACME #100) CHAIN OIL applied by brush or spout can.

CAUTION: BE CERTAIN TO FOLLOW ALL MANUFACTURERS RECOMMENDATIONS FOR APPLICATION AND SAFETY FOR ANY LUBRICANT AND CLEANING FLUIDS
The following figures show the recommended lubrication procedures and time schedule. It is suggested that the user keep a lubrication log. PLEASE READ BEFORE SERVICING YOUR PEDDIMAT PC/CNC SYSTEM.

CAUTION: TURN ALL POWER OFF BEFORE BEGINNING ANY SERVICE PROCEDURE. FOLLOW LOCK-OUT/TAG-OUT ANSI Z244.1-1982 AND OSHA CFR 1910.147. CAUTION: ANY GUARDS OR COVERS, WHICH MUST BE REMOVED FOR SERVICING MUST BE COMPLETELY RE-INSTALLED PRIOR TO MACHINE START-UP. (CAUTION): USE NON-FLAMMABLE CLEANING FLUID FOR CLEANING PARTS AND REMOVING EXISTING GREASE. MACHINES ARE NOT EQUIPPED WITH EXPLOSION PROOF CONTROLS OR ELECTRICAL DEVICES. (CAUTION): ALWAYS MAKE CERTAIN ALL MACHINERY COMPONENTS WILL MAINTAIN A SAFE POSITION DURING ALL SET-UP, MAINTENANCE AND REPAIRS, BY USING ADEQUATE PHYSICAL BLOCKING, RESTRAINT, AND CONTROL PROCEDURES. NEVER DEPEND UPON THE MACHINES HYDRAULIC OR PNEUMATIC POWER TO HOLD OR MAINTAIN ANY COMPONENTS IN A CONSTANT POSITION.

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7.1.1 X-Axis Drive Component Lubrication Information

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7.1.2 Y-Axis Drive Component Lubrication Information

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7.1.3 Typical Entry Vertical Material Hold-Down Roller Lubrication

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7.1.4 Horizontal Material Datum Clamping Lubrication Info.

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7.1.5 Triple-Tooling Mini-Ram Lubrication Information

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7.1.6 Plenum Chamber & Scrap-Cart Wheel Lubrication

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7.1.7 Plasma-Torch/Marker Vertical Travel Lubrication

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7.1.8 Punch Tooling/Rail Assembly Lubrication Information

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7.1.9 Cone Drive Gear Reducer (30:1 Ratio)

The following general information is based on Cone Drive/Textron specifications for size 40 single stage model gear reducers. General Information - Mechanical The input and output shafts of the reducer should be coupled to the motor and driven shafts with flexible couplings and the reducer then to be aligned with these shafts within + or .001. Failure to properly align shafts can result in excessive coupling and bearing wear, shaft deflection and eventual failure of one (1) or more of the components. Couplings, sheaves and sprockets should be mounted on the reducer shafts carefully. Do not pound or hammer them onto the shafts as this will damage bearings and oil seals. (NOTICE): FILL UNIT TO PROPER LEVEL WITH RECOMMENDED OIL. GREASE ALL FITTINGS WITH RECOMMENDED GREASE. IN THE CASE OF DOUBLE OR TRIPLE REDUCTION REDUCERS, BE SURE TO FILL EACH REDUCTION STAGE TO PROPER OIL LEVEL. Note: All reducers are built for one mounting position, i.e., floor mounted or wall mounted with worm vertical up or ceiling mounted, etc. If the reducer is to be mounted in any position other than the position for which it was furnished, contact Cone Drive for information on relocating oil level, grease packing bearings, etc., before start-up. If a reducer is operated in a mounting position other than the position for which it was assembled, reducer failure may occur from improper oil level or grease fitting location resulting in lack of lubrication to the gearset and bearings.

7.1.9.1 Start-Up
After the reducer has been properly mounted, aligned and lubricated, it is ready for start-up. Make sure driven machine is clear of all obstructions and all safety guards and covers are in place. If possible, turn motor shaft by hand to confirm drive system is operating freely and in correct direction of rotation. Jog motor to conform proper rotation. Operate reducer with minimum load for approximately 15 minutes (in both directions if applicable) to seat gears, bearings, and oil seals.

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7.1.9.2 Operation
All reducers require a few hours of run-in under load to achieve optimum efficiency. During this initial run-in, the reducer will probably run warmer than normal and draw more current than after the run-in period. Reducers operating at a very low load or speed will take much longer to run-in and even if operated continuously at low load or speed may never achieve the efficiency that they would if operated at or near their catalog rating. (NOTICE): NORMAL REDUCER OPERATING TEMPERATURE MEASURED ON THE OIL SUMP AREA OF THE HOUSING SHOULD NOT EXCEED 100 F. ABOVE AMBIENT TEMPERATURE OR 200F. IF THE REDUCER OPERATING TEMPERATURE EXCEEDS 200F SHUT DOWN THE UNIT AND CONTACT CONE DRIVE. EXCESSIVE OIL SUMP TEMPERATURE IS INDICATIVE OF OVERLOADING, MISALIGNMENT, OR IMPROPER OR MARGINAL LUBRICATION. CONTINUOUS OPERATION OF THE REDUCER WITH THE OIL SUMP TEMPERATURE ABOVE 200F. WILL RESULT IN BREAK-DOWN OF THE OIL AND FAILURE OF THE REDUCER.

7.1.9.3 Lubrication Data

Note: Lubrication is very imporatant for successful operation of Cone Drive gearsets and speed reducers. Inadequate lubrication can result in increased power consumption, added maintenance and gearset failure. Please review the following recommendations and the list of approved lubricants shipped with all Cone Drive gearsets and speed reducers. Type of Oil: Mobil #SHC-634 Synthetic Lubricant (or Equal) Preferred. (REFERENCE-Peddinghaus Part #:YD2307773) Note: For list of Cone Drive recommended lubricants and vendors, see CHART AT END OF CHAPTER. Lubricating oils for use in gear units should be high quality well refined petroleum oils. They must not be corrosive to gears, to ball, roller, or sleeve bearings; they must be neutral in reaction; free from grit or abrasives; and have good defoaming properties. As they may be subject to high operating temperatures, they must have good resistance to oxidation. For worm gears, additions of 3% to 10% of acidless tallow or similar animal fats are desirable.

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Ambient Temperature The recommended oils are for use in an ambient temperature range of approximately 15 to 125 F with the low end of the range depending on the pour point of the specific oil used. If the ambient temperature will be below or above this range, please contact Cone Drive for specific recommendations on proper lubricant as well as proper oil seal and shim materials. Sludge It is necessary that the oil be clean and free from sludge at all times to obtain long life from a gear unit. Sludge in gear units may be caused by excessive heat, from dust and dirt and other contaminates and by the presence of moisture or chemical fumes. Therefore, every precaution should be taken to prevent water and foreign particles from entering the gear case. Oil Change (Refer to Chart A, Which Follows) The oil in a new unit should be drained at the end of two weeks operation and the case thoroughly flushed with light flushing oil. The original oil can be used for refilling if it has been filtered, otherwise, new oil must be used. After this, a change of oil every 2500 hrs. of operation or every six months, whichever occurs first, is recommended for units operating under favorable conditions. Where operating conditions are severe, such as a rapid rise and fall of temperature of the gear case with accompanied sweating of the inside walls and resulting formation of sludge, or where operation is in moist or dusty atmospheres, or in the presence of chemical fumes, it may be necessary to change the oil at intervals of one to three months. Oil Level Cone Drive reducers are furnished with either a bulls eye type sight glass or a bronze or yellow pipe plug to indicate oil level. In either case an oil level tag is affixed to the unit near the oil level indicator. OIL LEVEL SHOULD ALWAYS BE CHECKED WITH THE UNIT STOPPED. Estimated oil capacities for standard reducers are listed on Chart A. Grease Packed Bearings Bearings that are at least partially submerged in oil or oiled by internal oil scoops do not require special maintenance. However, bearings that are not lubricated as above require grease lubrication. Grease fittings and internal retainers are furnished when required. They should be greased with a high quality lithium base NLGI#2 or NLGI#3 bearing grease at normal maintenance intervals depending on the duty cycle of the reducer.

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OIL CAPACITIES Approximate Capacities in Gallons (Per Cone Drive) Single Reduction Reducers - Floor Mounted Position (30:1 Ratio) FPB MODEL NUMBER FPB 1500/3C or FPB 1500/3D &E or FPB 500/3E or FPB 1800/3A Reducer Size & (Quantity) 40 (2) Worm Under Gear HU Approx. Oil Capacity (Each) 1 1/2 Gal

(NOTICE): DO NOT OVERFILL UNITS. FILL TO CENTER LINE OF OIL GAUGE OR TO PIPE PLUG IDENTIFIED WITH OIL LEVEL STICKER. OIL CAPACITIES WILL VARY DUE TO MOUNTING POSITIONS OR TYPE OF GEARSHAFT MOUNTING USED, SUCH AS SOLID SHAFT, HOLLOW SHAFT OR SPREAD BEARINGS.

7.1.9.4 For Replacement of the Cone Drive:

Cone Drive Reducers are Shipped Without Oil. After assembly, all reducers are test run with a rust-inhibiting oil and drained. This oil coats all internal parts and will protect the reducer for a period of 30 days. If the unit is to be stored longer than 30 days, please contact Cone Drive for storage instructions. List of Lubricants & Vendors (Recommended by Cone Drive) (SEE CHART AT END OF CHAPTER) For Double-Enveloping Worm Gear Speed Reducers & Gearsets Ball and roller bearing grease. * American Oil Co., Rykon #2EP grease. * Mobil Oil Co., BRB Lifetime grease.

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Moly-Disulfide paste grease. * Dow-Corning Corp., Molykote BR-2S.

Hydraulic Oil * American Oil Co., #15 Industrial Oil. * Mobil Oil Co., DTE #24 Industrial Oil.

Pneumatic Oil * Gardner-Denver Co., #A-51 Air Lube Oil. * American Oil Co., Grade C Spindle Oil. * Mobil Oil Co., Velocite #6 Spindle Oil.

7.1.9.5 Gear Reducer Maintenance

The reducer oil level should be checked weekly and the recommended oil added as required to maintain the proper oil level. The oil should be changed as outlined in the lubrication section. All grease fittings should be lubricated with the recommended grease once per month. The reducer, particularly finned areas and fan covers, should be kept clean to allow maximum heat dissipation. All reducer and foundation bolts should be checked for tightness after three (3) months of service and anually thereafter. If a reducer has to be repaired, contact Cone Drive for detailed instructions, blueprints, parts lists, etc.

7.1.10 Ball Screw Assembly Lubrication

(See Figure 7.1.2, page 7-4) Axis ball screws should be lubricated to maximize life. Use Nook E-900 Ball Bearing Screw Lubricant (or equivalent), a light oil (10W30), or lithium grease to provide adequate lubrication for moderate duty. The lubricant should be applied generously on the entire length of the screw (Rotate screw to expose screw area under nut). By keeping the ball screws lubricated it will provide a lasting film for anti-wear protection and offer a resistance to corrosion & oxidation.

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7.1.11 Pneumatic Lubrication

Mist Lubricator Filling Operation & Service Filling - Inlet pressure must be eliminated before fill plug is removed. Fill to fill line on the bowl with oil of 100 to 200 SSU viscosity at 100 F and an aniline point greater than 200 F, same as SAE No. 10 (petroleum base hydraulic oils or spindle oils are good examples). 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 - excessive torque is not necessary. The lubricator is now ready for setting. Repressurize the lubicator. OIL DELIVERY ADJUSTMENT - to adjust oil delivery, use a slotted screwdriver to turn the adjusting screw in the top of the lubricator.

Leaner - Clockwise Richer - 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 sight dome go downstream; adjust drip rate accordingly. Consult oil delivery conversion chart. 25 drops per minute equals one ounce per hour - volume of oil passing through sight dome. 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 NEEDLE VALVE SETTING BE CHANGED AFTER YOUR INITIAL SETTING.

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Your PEDDIMAT CNC system has an intermittant 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 Operation & Service 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.

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The filter element should be removed and replaced when the pressure differential across the filter unit is excessive. To remove the filter element: SHUT OFF AIR SUPPLY and depressurize the unit. * * * * * * Unscrew threaded bowl. Unscrew lower baffle and remove filter element and gaskets (2). Clean all internal parts, bowl and element before re-assembling. See polycarbonate bowl cleaning section below. Install element and gaskets (2). Attach lower baffle and tighten firmly. Replace bowl seal; lubricate seal to assist in retaining it in position. Use only mineral base oils or grease. Do NOT use synthetic oils such as esters and do NOT use silicones. Screw bowl into body.

TO CLEAN POLYCARBONATE BOWLS USE MILD SOAP AND WATER ONLY! DO NOT use cleansing 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. For servicing of filter, regulator and oiler, see Section 7.4.4.(page 7-38).

7.2 Care And Maintenance Of The Mechanics

PLEASE READ BEFORE SERVICING YOUR PEDDIMAT CNC SYSTEM. (CAUTION): TURN ALL POWER OFF BEFORE BEGINNING ANY SERVICE PROCEDURE. FOLLOW LOCK-OUT/TAG-OUT ANSI Z244.1-1982 AND OSHA CFR 1910.147.

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(CAUTION): ANY GUARDS OR COVERS WHICH MUST BE REMOVED FOR SERVICING MUST BE COMPLETELY RE-INSTALLED PRIOR TO MACHINE START-UP.

(CAUTION): ALWAYS MAKE CERTAIN ALL MACHINERY COMPONENTS WILL MAINTAIN A SAFE POSITION DURING ALL SET-UP, MAINTENANCE AND REPAIRS. BY USING ADEQUATE PHYSICAL BLOCKING, RESTRAINT, AND CONTROL PROCEDURES. NEVER DEPEND UPON THE MACHINES HYDRAULIC OR PNEUMATIC POWER TO HOLD OR MAINTAIN ANY COMPONENTS IN A CONSTANT POSITION.

7.2.1 Service/Repair Parts

Peddinghaus Service Department Structure Peddinghaus Corporation maintains a complete staff of service technicians who are familiar with the mechanical, electrical, and pneumatic and hydraulic function of this CNC system. Their many years of experience in dealing with systems of this nature puts them in the unique position to be able to assist in identifying any problems you may be experiencing with your Peddimat CNC system. If you require replacement parts only for your servicing needs, then call our ORDER ENTRY DEPARTMENT. If troubleshooting assistance is required, then contact our SERVICE DEPARTMENT. When contacting our personnel for assistance, please be prepared to give the name of your company and the machine system in question. With this basic information, our technicians will be able to access, by computer, your service file to become familiar with the history of your installation, machine vintage, software being utilized, type control, drives, etc. This type of information, with the assistance at your end, enables us to either solve the problem or determine what parts are required to rectify the present situation.

7.2.2 Ordering Spare Parts (Order Entry Department)

When dealing and contacting the Peddinghaus Corporations Order Entry Department, it is extremely beneficial if you have the appropriate piece part drawing or assembly drawing in front of you prior to placing the call. Our sales technician will immediately be able to access the same assembly drawing to synchronize the replacement part requirement.

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(CAUTION): USE ONLY AUTHORIZED PEDDINGHAUS REPLACEMENT PARTS. FAILURE TO DO SO CAN REDUCE THE FUNCTIONALITY OR RELIABILITY AND SAFETY TO THIS SYSTEM. THIS CAN LEAD TO SERIOUS INJURY OR EVEN DEATH, NOT ONLY TO THE MACHINE OPERATOR , BUT ALSO TO OTHER EMPLOYEES.

7.2.3 Returning Spare Parts For Credit

No item that is returned to Peddinghaus Corporation will be accepted without prior authorization. If it arrives at our facility without a return authorization number, it will be refused and returned to the sender. To receive such a return authorization number, please call (815) 937-3800, FAX (815) 937-4003 or write Inside Sales for instructions and return authorization number. The return authorization number must be shown on the outside of the package of any parts that are being returned.

7.2.4 Assembly Drawings

Section 8 contains actual assembly drawings and bills of material used to construct your PEDDIMAT CNC system. These drawings will be useful for replacement parts, adjustments, and understanding the operation of the various mechanisms. Each drawing is accompanied by a bill of material. Matching the ballooned number with the items on the bill will help you to determine part numbers for servicing. Hardware numbers are listed as C1, C2, C3, etc., on the bill of material. (NOTICE): FASTENERS NOT SPECIFICALLY DESIGNATED ON THE ASSEMBLY DRAWINGS SHOULD BE HANDLED AS PRESCRIBED IN THE FOLLOWING SECTIONS ON FASTENERS, LOCTITING AND FASTENER TORQUES. BE CERTAIN TO FOLLOW ALL PRECAUTIONARY NOTES FOUND ON THESE DRAWINGS, AS WELL AS SAFETY PROCEDURES DOCUMENTED IN OTHER PEDDINGHAUS CORPORATIONS MANUALS PROVIDED TO YOU.

7.2.5 Fasteners
In order to maintain the proper operation and safety of Peddimat CNC systems, it is important to understand the use of fasteners in their design. During the repair or re-assembly of any components, it is important to replace all fasteners as they were originally installed.

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The following parameters must be followed.

Hex head capscrews are grade 5 or better. Use full or jam nuts as originally applied. Socket head capscrews are UNBRAKO brand from SPS Technologies and are a minimum of 180,000 PSI tensile. Lockwashers, flatwashers, cotter pins, and roll pins must be replaced as found. Do not substitute roll pins for dowel pins. Length of thread engagement is critical and must be maintained. Fasteners which require a special torque applied will be indicated as such on additional maintenance instructions found in this manual. Fasteners which require a special loctiting application will be indicated as such on additional maintenance instructions found in this manual.

7.2.6 Loctite
Fasteners are loctited to assure proper and safe machine operation. The maintenance department should not neglect these practices during the repair or re-assembly of any Peddimat system. Be certain to follow all instructions and safety precautions as stated by the Loctite Corporation when using their products. Normal machine operation may cause a loosening of some fasteners, or maintenance may require the removal of some fasteners. These may be re-assembled with loctite as follows: If previously loctited, removing existing loctite with wire brush. For fasteners smaller than 1/4 thread, loctite #222 purple may be used. For fasteners 1/4 thread and larger loctite #242 blue may be used. This includes hex, slotted, counter-sunk, flat head & shoulder bolts. Also for use with fasteners into aluminum. For fasteners 1/4 thread and larger that are made of high strength alloy (UNBRAKO type) use loctite #262 red if additional maintenance sheets indicate the use of this loctite. Loctite acts as a lubricant and torque values should be based on this fact. On blind threaded holes, place the loctite into the hole not on the fastener. Because of the setting time of loctite, use primer N for maintenance applications.

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Loctite #262 may be used for securing keys into keyways. Pneumatic/Hydraulic Seal 545 may be used to secure and seal air and hydraulic lines. USE TEFLON TAPE ON ACETYLENE OR OXYGEN FITTINGS, DO NOT USE LOCTITE SEAL 545 OR PST.

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7.2.7 Fastener Torques

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7.2.8 Torque Specifications of Specific Machine Components

7.2.8.1 Punch Cylinder Tie-Rod Torque Specifications

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7.2.8.2 X-Axis Drive Motor Flex-Couplg & Ringfeder Torque Specs.

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7.2.8.3 X - Axis Motor Flex-Coupling Torque Specifications

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7.2.8.4 Linear Bearing Unit Loctite Directions/Illustration

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7.2.9 Painting
(NOTICE): THE REPAINTING OF THE VARIOUS MACHINE ELEMENTS SHOULD FOLLOW THE GUIDELINES AS PRESCRIBED IN THE FOLLOWING SECTION ON PAINTING. The color scheme of Peddinghaus Corporation Peddimat CNC systems use several types of acrylic and acrylic enamel paints. Although it may not be possible to achieve the same original factory paint appearance, here are some guidelines to assist with any general repainting which might be required. Gray automotive type primer. Green coating 10-2-098 non-lead by Jordans Paint Manufacturing of Forest Park, Illinois. Green coating for electrical cabinets & standup Peddimat machines is an acrylic enamel (for high gloss). Orange coating for certain moving machine elements is an acrylic enamel. Clear urethane coating over control console panels. 1200F high temperature black (wherever this paint was originally used). The Peddimat purchaser may have specified a certain color or paint other than our standard.

The use of these paints is for several reasons. The basic color scheme is for Peddinghaus Corporation product recognition. The quality of the paint product assures ease of clean-up for good housekeeping. Orange color is used to designate certain moving machine elements. High temperature black offers component protection for certain components which operate at above ambient temperatures. It is also used where thin coat paint protection is required.

Repainting If repainting is required, follow the original machine paint scheme, and use the following as guidelines. Orange machine elements should remain that color for general machine safety. Use high temperature paints where above ambient temperatures are encountered.

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Do not allow paint to get into bushings, shafts, rotating or sliding mechanisms, or on guideways. Do not paint on grease fittings or openings. Do not allow paint to get into electrical components, control buttons, limit or proximity switches, or switch light reflectors. Do not paint over any warning signs, labels, product identification, control tags, instructions, or air filters. Paint should never interfere with the intended function of the machine or cause an unsafe operating condition.

7.3 Care & Maint. of Original Equipment Mfg. Devices

7.3.1 Cone Drive Gear Reducer
Refer to Section 7.1.9.5. for maintenance of the gear reducer and Section 7.1.9. for complete information.

7.3.2 Hypertherm Plasma-Arc Cutting System Maintenance

7.3.2.1 Torch Coolant Data & Filling Instructions
NOTE: The power supply is shipped without any coolant in the tank. (SAFETY NOTICE): OBSERVE SAFETY WARNINGS REGARDING THE USE, HANDLING AND STORAGE OF PROPYLENE GLYCOL. THIS INFORMATION IS PROVIDED IN APPENDIX B OF THE OF THE HYPERTHERM MACHINE TORCH INSTRUCTION MANUAL. Be sure the torch leads are connected. Always add coolant to the Hypertherm Plasma System with the power OFF. Fill the tank with coolant until the level reaches the bottom of the neck, approximately 2.9 gallons (11 liters). A mixture of ethylene glycol (25%) and deionized water (75%), which resists freezing to +10 F. (-12C) is recommended.

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(CAUTION): FOR OPERATING TEMPERATURES COLDER THAN THE +10 F.(12C) TEMPERATURE STATED ABOVE, THE PERCENTAGE OF PROPYLENE GLYCOL MUST BE INCREASED. FAILURE TO DO SO COULD RESULT IN A CRACKED TORCH HEAD, HOSES, OR OTHER DAMAGE TO THE TORCH COOLANT SYSTEM DUE TO TORCH COOLANT FREEZING. (CAUTION): ALWAYS USE PROPYLENE GLYCOL IN THE COOLANT MIXTURE. DO NOT USE ANTI-FREEZE IN PLACE OF PROPYLENE GLYCOL. ANTI-FREEZE CONTAINS CORROSION INHIBITORS WHICH WILL DAMAGE THE TORCH COOLANT SYSTEM. ALWAYS USE DEIONIZED WATER IN THE COOLANT MIXTURE IN ORDER TO PREVENT CORROSION IN THE TORCH COOLANT SYSTEM. The operator should periodically monitor the coolant status LED lights during cutting operations for coolant system malfunction indications. (Refer to Panel C figure, in Section 1, page 1-3 of this manual).

Refer to the Maintenance section of the applicable Hypertherm Plasma System Instruction Manual supplied by Hypertherm Corporation, the system manufacturer, for additional troubleshooting and maintenance information. If you need additional assistance, call Hypertherm Corporation at their Customer Service or Technical Service Group Number; 1-800-643-0030. (WARNING): BE SURE TO READ AND OBEY ALL SAFETY AND SHOCK HAZARD WARNINGS, GIVEN IN THE HYPERTHERM INSTRUCTION MANUAL AS PREVIOUSLY SPECIFIED, BEFORE ATTEMPTING ANY SERVICE/MAINTENANCE OF THE POWER SUPPLY AND/OR THE ENTIRE PLASMA SYSTEM.

7.3.2.2 Pneumatics/Filtration
The pneumatic filter regulator/lubricator pressure should be adjusted and set to 90 psi (620 kilopascals). Adjust oil lubricator to drip oil into the system for normal punching operation per instructions given previously in Section 7.1.11., Pneumatic Lubrication, page 7-16. Drain all pneumatic filters at the start of each work shift. Refer to Figure PUSHNDRAIN, page 7-18 for procedure and fill air oil lubricator if needed.

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Filter Replacement Information Air separator/filter assembly- Hankison Centriflex Model Ref: Peddinghaus part #YD2306704. Replacement cartridge depends on model supplied by vendor, contact Hankison with the model # from the housing on your machine. (Examples of Models that have been supplied by Hankison are #C15-03F-16M, #C18-03-16 or #HF9-12-3 and for cartridges #0734-1 or #E9-12.) Oil removal filter assembly - Hankison Aerolescer Coalescent Model Ref: Peddinghaus part #YD2306705. Replacement cartridge depends on model supplied by vendor, contact Hankison with the model # from the housing on your machine. (Examples of Models that have been supplied by Hankison are #A10-03F-16M, #A1803-16 or #HF5-12-3 and for cartridges #0713-2, #E5-16-03 or #E5-12.) Recommended cartridge replacement data based on pressure drop parameters as follows: New - Initial (dry): 1 psi (7 kilopascals) maximum. Replace at: 10 psi (70 kilopascals) or above.

(NOTE) FILTERS ARE VERY IMPORTANT FOR QUALITY PLASMA CUTTING. BE SURE TO MANUALLY DRAIN ABOVE FILTERS PERIODICALLY

7.3.3 Torit Model DFT 2-8 Filtration System Maintenance

7.3.3.1 Filter Cartridge Monitoring
The replacement of the (4) cartridge filter elements, which use an efficiently pleated Thermotek synthetic media, may be determined by monitoring the magnahelic gauge mounted to the side of the filtration cabinet. This gauge monitors the pressure drop across the filter cartridges and is calibrated in inches of water. The following is a general description of magnahelic gauge movement and what this movement represents relative to filter(s) condition. Note that the various gauge movements described are installation and usage dependent and may vary from installation to installation. Careful monitoring of the magnahelic gauge and filtration usage at each individual installation will render the magnahelic gauge most useful for determining the optimum filter changing schedule.

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Initially, the magnahelic gauge will rise slowly from the low end of gauge (when new/clean filters are present) to a higher reading and then proceed to level off. This leveling off indicates that the filters have reached their characteristic stabilization level. Higher gauge movement from this level should proceed at an extremely slow rate of climb (it may be imperceptable) depending on amount of filtering demand. Finally, a fairly rapid rate of gauge movement, climbing towards the full-scale reading is indicative of nearly or completely clogged filter elements and signals filter changing time. A representative curve depicting the previous description of magnahelic gaugepointer movement would look like Figure A below.

7.3.3.2 Filter Cartridge Replacement

When it is time to replace the filter cartridge elements, proceed as instructed in the Torit Installation & Operation Manual, a copy of which is included with each unit shipped by Torit Mfg. Co. Element Replacement is covered in the Service section of this manual. Note any Cautions, Warnings, etc., which apply to this servicing operation. (CAUTION): DUST LADEN FILTERS MAY BE HEAVY & DIFFICULT TO HANDLE WHEN REMOVED THROUGH THE ACCESS DOOR OPENING. Be sure to exercise safe working practices, especially if performing this service from a ladder.

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7.3.3.3 Replacement Cartridge (Qty. 4 Required)

The replacement cartridge element part number is #8PP-45368-00 (Peddinghaus Part # YD2308039). The service temperature rating of this cartridge is 275 F (135 C).

7.4 Care And Maintenance of Hydraulics And Pneumatics

7.4.1 Cylinders
The assembly drawings indicate part numbers for various packings of Peddinghaus manufactured cylinders. Also on the assembly drawings are part numbers for rod and piston seal kits of stock cylinders.

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7.4.2 Hose, Tube and Pipe Specifications

The following component specifications are required as minimums when replacing any hose, tubes or pipes on your Peddimat CNC system.

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7.4.3 Hydraulic Power Unit

7.4.3.1 Hydraulic Reservoir Data
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. The replacement filter numbers are found on the filter canister itself. The filter has a clogged filter indicator which will rise when the filter is not clean.

7.4.3.2 Changing the Hydraulic Oil

Prior to changing the hydraulic oil, the machine must be shut off and any accumulators must be relieved. FAILURE TO DO SO CAN CAUSE SERIOUS INJURY OR DEATH. The first hydraulic oil must be changed after 1000 working hours (see hour meter in switch cabinet). Future oil changes must be carried out after 2000 hours or no later than one year. The reservoir holds 120 gallons (455 liters) of oil.

7.4.3.3 Hydraulic Oil Data

Suggested hydraulic oils are selected for their properties of viscosity range, anti-wear, oxidation resistance, and foam inhibitors. Upon installation, all hydraulic functions are cycled manually to remove trapped air from the system. Top Off the reservoir fluid level to maximum Full in the sight gauge indicator before automatic operation. 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.

7.4.3.4 Hydraulic Oil Types And Reservoir Level

Mobil DTE #24 or Duro AW Oil 32 Should the oil level sink below the minimum mark, then the tank must be immediately replenished.

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7.4.3.5 Pressure Adjustments/Filter Changing

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 terminate immediately. Install a new filter after 1000 hours of operation and replace thereafter when the dirty filter indicator is observed on the power unit. Suction strainer should be cleaned at each oil change.

7.4.4 Pneumatics
For operation of filter-regulator-lubricator, see Section 7.1.11 (Pneumatic Lubrication) Parker Filter 07F SPARE PARTS Element kit 40 micrometer; filter, seal, gasket: Parker #PS201P Element cartridge kit 40 micrometer; holder, filter, gasket, baffle shroud, deflector, seal, body seal, Parker #PS204P Polycarbonate Bowl Kit; bowl with drain, seal, Parker #PS205P

Safety: Transparent Bowls CAUTION: Polycarbonate bowls, being transparent and tough, are ideal for use with filters and lubricators. They are suitable for use in normal industrial environments, but should not be located in areas where they could be subjected to direct sunlight, an impact blow, nor temperatures outside of the rated range. As with most plastics, some chemicals can cause damage. Polycarbonate bowls should not be exposed to chlorinated hydro-carbons, ketones, esters and certain alcohols. They should not be used in air systems where compressors are lubricated with fire-resistant fluids such as phosphate ester and di-ester types. Metal bowls are recommended where ambient and/or media conditions are not compatible with polycarbonate bowls. Metal bowls resist the action of most such solvents, but should not be used where strong acids or bases are present or in salt laden atmospheres. Consult the factory for specific recommendations where these conditions exist.

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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. Parker Regulator OTR Spare Parts: Poppet Kit; poppet and relief tube assembly, cap seal. Parker #PS212P Relieving Piston Kit; seal piston, piston. Parker #PS110P Gauge, 0-160 PSI; Parker #P781642 Control Spring, 2 to 125 PSI, Parker #P78482

Servicing NOTE: SHUT OFF AIR SUPPLY AND DEPRESSURIZE ALL AIR LINES CONNECTED TO THE REGULATOR. To service the piston or control springs, turn the adjusting handle counterclockwise until compression is released from pressure control spring. * * * * On the 06R and 07R Series, remove bonnet by unscrewing bonnet from body and removing the control spring, piston, and piston seal. Clean and carefully inspect parts for wear and/or damage. If replacement is necessary, use parts from the service kits. Lubricate the piston seal with a mineral base oil or silicone grease. DO NOT use synthetic oils such as esters. Install piston, piston seal, control spring, and adjusting screw pressure plate. On the 06R and 07R Series, screw bonnet to body and tighten to 50 to 75 inch-pounds torque.

To service poppet and relief tube: * * * Relieve all pressures as described in above NOTE: Remove cap by unscrewing from body (located opposite from control spring bonnet). Remove poppet relief tube and balancing spring. Clean and carefully inspect parts for wear and damage. If replacement is necessary, use parts from service kit.

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Lubricate cap seal as listed above, install in groove of cap and screw cap into body.

Turn on air supply and adjust to desired secondary pressure as described in step 1 in Operation.

Parker Micro-Mist Lubricator 17L Spare Parts: Body Service Kit, Parker #PS231BP. Replacement Bowl Kit; polycarbonate bowl with manual drain, seal, Parker #PS225P.

NOTICE: SEE PREVIOUS PARAGRAPH ON SAFETY: TRANSPARENT BOWLS. Pneumatic Lubricants Gardner-Denver Co. #A-51 Air Lube Oil American Oil Co. Grade C Spindle Oil Mobil Oil Co. Velocite #6 Spindle Oil

7.5 Care and Maintenance of Electricals

Checks and maintenance work on the electric and electronic equipment should only be carried out by authorized expert personnel. We would like to recommend once again that you take out a customer service contract with us. By doing so, you will have the guarantee that the machine, in particular the electric and the electronic equipment, is maintained and serviced by expert personnel.

7.5.1 Care and Maintenance of the Control Console

Make a functional check of the operating controls every year.

7.5.2 Primary Current

Clean disconnect and components every six months Check all connections once a year Check and adjust control and auxiliary voltages once a year

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7.5.3 Interface Axis Servo Drives

Clean foam filter material weekly Clean all plug boards every six months. (Every three months in cases where large amounts of dust exist). Check all connections once a year Make adjustments once a year

7.6 Care and Maintenance of General Components

Limit switches and proximity switches should be kept clean Check wiring for mechanical damage every six months Check all connections every six months Check encoder fixtures and couplings every six months

7.7 Maintenance Check List

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8. ASSEMBLY DRAWINGS & BILLS OF MATERIAL

The following assembly drawings were used to assemble your Peddimat CNC system. They are provided here to assist you with general maintenance and repair The Hydraulic Power Unit Maintenance Book and Parts List is found separately in the control consoles door.

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