manual peddinghaus

Operating Instructions for the Peddimat tandem Saw/Drill Line

Peddimat – BDL 1000/9

Table of contents

Drilling Line BDL 1000/9

FUNDAMENTAL NOTES 1

FUNDAMENTAL NOTES ON SAFETY 2

TRANSPORTATION, STORAGE AND DELIVERY 3

TECHNICAL SPECIFICATIONS 4

INSTALLATION, ASSEMBLY AND INITIAL START-UP 5

OPERATING THE MACHINES 6

TOOLS 7

THE SIGNOSCRIPT MARKING UNIT (OPTION) 8

MAINTENANCE AND SERVICING 9

CHANGING THE SAW BLADE 10

THE SIGNOMAT MARKING UNIT (OPTION) 11



MEBA BAND SAW (OPTION) 12

CONFORMITY AND MANUFACTURER’S DECLARATIONS 13

PART 2 OPERATING MANUAL; CIRCUIT DIAGRAMS;

BILLS OF MATERIAL

B

Operating Instructions for the Peddimat tandem saw/drill line

Peddimat – BDL 1000/9 Chapter 1 / 1

Table of contents Chapter 1

Fundamental notes

1.1 Foreword 1 – 2

1.1.1 Customer service 1 – 2

1.2 Intended use 1 – 3

1.3 Warranty and liability 1 – 3

1.4 Brief description and machine function 1 – 4

1.4.1 The drilling machine 1 – 4

1.4.2.1 Options 1 – 4

1.4.2 Mechanical assemblies 1 – 4

1.4.3 Electrical components 1 – 5

1.4.3.1 The CNC control 1 – 5

1.4.3.2 The power section 1 – 6

1.4.3.3 The axis drives 1 – 6

1.4.3.4 The axis feedback section 1 – 6

1.4.4 Hydraulic components 1 – 7

1.4.5 Safety equipment 1 – 8

1.5 Special installation instructions for the user 1 – 8

1.6 Publication, date of issue of the manual 1 – 8

1.7 Copyright 1 – 8

1.8 Manufacturer’s address 1 – 8



1 FUNDAMENTAL NOTES

1.1 Foreword

This operating manual contains information and details necessary for the operation and

maintenance of your Peddimat tandem saw/drill line.

The Peddimat saw/drill line represents equipment incorporated in the Peddinghaus

range of products. Series design, years of experience in machine tool building coupled

with modern production and testing methods guarantee a high standard of quality to-

gether with reliable operation and long service life.

Always observe all notes on safety, and the pertinent operating and maintenance instruc-

tions.

This instruction manual contains all the information required for operating the

machines. The handbook for the Siemens control ( Sinumerik 840D ) is part and

parcel of this manual..

This manual is intended for technically qualified, specially trained operators or for opera-

tors with in-depth knowledge in the field of NC technology.

Full knowledge and technically competent implementation of the safety instructions and

warnings are a pre-requisite for non-hazardous installation and commissioning as well as

for safe operation and maintenance. Only qualified personnel have the necessary

specialist knowledge to interpret and implement the safety instructions and warnings in

case of an emergency.

1.1.1 Customer service

The Peddinghaus Service Department is at your disposal to assist in remedying technical

problems.

Tel. + 49 (0) 2332 – 72 – 0

Fax. + 49 (0) 2332 – 72 – 208



1.2 Intended use

The Peddimat saw/drill line is to be used solely for processing of structural sections

and flat bar by sawing, drilling, pop marking and marking in accordance with previously

compiled parts programmes. Only operate the machine when it is in technically perfect

condition and only for performing the work for which it is designed. Always observe all

safety, operating and maintenance instructions set forth in this manual and be aware of

potential dangers. Faults affecting safety, in particular, are to be remedied immediately.

The Peddimat saw/drill line is only to be used in:

♦ automatic cycle

♦ manual in-feed

♦ manual part removal

mode!

The machine can only be started by using the :

♦ starting facilities on the controls (control consoles)

The machine may be operated by several operators .

Proviso: ♦ authorisation must be given for several operators to operate

the line (refer to Chapter 2.7.)

The following norms ( standards ) were taken into consideration in the design of the

saw/drill line, the individual machines and their safety equipment:

♦ DIN EN 292 – 1/ 2 / 953 / 954-1 / 1088 / 50100 / 60204-1

Any use other than that described above is considered not to be in accordance with

the intended use!

Messrs. Paul Ferd. Peddinghaus GmbH are not liable for any damage that may

result from such improper use.

Intended use also encompasses:

♦ observance of all instructions in the manual and

♦ adherence to all inspection and maintenance instructions

1.3 Warranty and liability

Our “Conditions of sale and supply” apply. Warranty and liability claims in case of injury

to persons or damage to property are excluded when they are to be traced back to one

or several of the following causes:

♦ not using the machine for its intended purpose;

♦ improper installation, start-up, operation and maintenance of the machine;

♦ operation of the machine when safety equipment is faulty, not fitted properly or does

not function correctly.

♦ non-compliance with the instructions in the manual in respect of transportation,

storage, installation, start-up, operation, maintenance and machine set-up;

non-authorised modification of the machine parameters and / or of the drive parame-

ters set at the factory;

♦ inadequate monitoring of machine components subject to wear;

♦ improper repairs;

♦ cases of disaster caused by the effects of foreign bodies and Act of God;



1.4 Brief description and machine function

The Peddimat saw/drill line is a modern , CNC controlled machining centre designed

for the automatic sawing, drilling, pop marking and marking of structural steel sections

and flat bar.

The system consists of the following assemblies:

♦ Drilling machine

υ Band saw ( option )

υ Circular cold saw LC 1250 (option)

υ Signomat (option) or Signoscript (option )

υ CNC control

♦ Hydraulic power-pack

♦ Out-feed conveyor ( option )

♦ In-feed conveyor ( option )

υ Cross transfer table ( option )

1.4.1 The drilling machine

The drilling machine consists of:

♦ 3 drill assemblies

♦ roller feed, clamping and disc measuring system

♦ hydraulic power-pack

♦ hydraulic drive for the working and pressure cylinders and for the drill feed units

♦ CNC control

♦ Power section for the drilling and positioning drives with machine interface

1.4.1.1 Options

The following optional equipment is available for link-up to the drilling machine:

υ Band saw MEBA

υ Circular cold saw LC 1250

υ Signomat

υ Signoscript

υ In-feed conveyor

υ Out-feed conveyor

υ Cross transfer table

Options and additional equipment in accordance with the order acknowledgement.

1.4.2 Mechanical drilling machine assemblies

The Peddimat BDL 1000/9 is of robust steel plate design with a welded base frame

and a superstructure of welded and bolted plate design. The machine is equipped with 3

drill assemblies each with 3 spindles and an air cooling system through the spindles for

the drills.

The material is traversed in the X-axis by a high-precision, high-speed disc measuring

system with roller feed.



1.4.3 Electrical components

1. CNC control and console

2. Power cabinet

3. Axis drives

4. Axis feed-backs

5. System wiring and electrical components

1.4.3.1 The CNC control

The CNC control serves to take over and store the required data in the form of parts

programmes. The positioning drives are controlled and all commands for drilling opera-

tions issued by the CNC control in accordance with the programme organisation.

The control console contains all function and signalling components ( switches and signal

lamps ).



1.4.3.2 The power section

The power section is located in the switch cabinet (depending on model ) and contains all

switchgear and protective equipment for controlling the drive units such as drill motors,

adjuster motors and the hydraulic pump motor. All hydraulic valves contained in the sys-

tem are controlled by power amplifiers.

Several control transformers generate the required control and auxiliary voltages. All

master fuses are located on an appropriate board.

1.4.3.3 The axis drives

The power amplifiers for the digital positioning drives of the material feed X-axis and the

(W,Y and Z ) drill axes, the power sections for the main spindle drives, the saw axis,

the Signo axis and the hydraulics ( proportional valve, hole tapping and drill feed ) are

located in the CNC cabinet.

1.4.3.4 The axis feed-back section

The axis feed-back section is arranged in the CNC cabinet. and is responsible for

processing and switching the positioning feed-back signals.



1.4.4 Hydraulic components

The saw/drill line is equipped with a separate hydraulic power-pack complete with valve

manifolds for the following control functions:

Clamping and

measuring rolls

Z – side

15 – 80 bar

Internal clamp

Z – side

50 bar

Klemmvorrichtung

W – Seite

50 bar

Niederhalter

20 – 50 bar

Internal clamp

W – side

50 bar

Hold-downs

20 – 50 bar



1.4.5 Safety equipment

The safety equipment must protect all persons or objects against the hazards emanating

from the machine. They are co-ordinated and installed in conjunction with the user and

site conditions.

The following safety appliances can be installed:

♦ Protective barriers (fixed, partition fencing );

♦ Safety gates (movable, partition gates with or without locks);

♦ Guards;

♦ Non-contact safety appliances (BWS);

♦ Colour floor marking;

♦ Warning signs and warnings;

1.5 Special installation instructions for the user

The machine is to be installed and assembled by personnel well acquainted with electro-

magnetic compatibility. The installation and assembly drawings provided by the suppliers

of the appliances, systems and components are to be observed, thus guaranteeing

perfect operation of the overall system

It is a Class A machine. Special arrangements are to be made for installation of

the machine in residential, business or factory areas as well as for small

businesses.

The user is responsible for any electro-magnetic disturbances which can ema-

nate from the machine when the instructions in respect of installation are

ignored.

1.6 Publication, date manual issued

First edition 01 / 2003

1.7 Copyright

The copyright on this instructions manual remains with Messrs. Paul Ferd. Pedding-

haus GmbH. The manual is only intended for the user and his staff.

It contains instructions and notes which are neither to be

♦ reproduced

♦ distributed nor

passed onto third parties either in part or in full.

Violation of these regulations can result in prosecution.

1.8 Manufacturer’s address

Company: Paul Ferd. Peddinghaus GmbH

Address: D-58285 Gevelsberg, Hasslinghauser Str. 156

Tel. + 49 (0) 2332 – 72 – 0

Fax. + 49 (0) 2332 – 72 – 208

Warning!

Drilling Line BDL 1000/9 Operating Instructions

Peddimat – BDL 1000/9 Kapitel 10 / 1


Changing saw blades (LC 1250)

10.1 Preparations 10 – 2

10.2 Changing the blade 10 – 2

10.3 Chip remover 10 – 4

10.3.1 Changing the chip remover 10 – 4

10.3.2 Adjusting the chip remover 10 – 4



10.1 Preparations

The following steps must be taken to change the saw blade:

Pre-conditions:

Key 12 >

Main switch is on

Control voltage is on

• the LED display is on

Action: − press key „ Control Off „ on control console

• the control and hydraulics are turned off

• the LED lamp above the key lights up

• the safety gate is unlocked and released

− open safety gate

− change blade

− change chip remover, if necessary

− close safety gate

− press key „ Control ON „ on control console

• the control and the hydraulics are turned on


− press key „ Delete error „ on control console

− press key „ Secure system „ on control console

• the safety gate is locked


The gearbox must be manually traversed to be able to change the blade; the blade is

now easily accessible.

Carry out the following operations:

• press "JOG" , LED lights up.

• press key "V" axis, LED lights up.

• press directional keys "Plus" or "Minus"

• Move the gearbox such that the complete cover

is out of the area of the vertical head support.

• press key "Enter danger zone".



♦ Observe the safety regulations and general instructions on safety.

♦ Wear your personal safety apparel (ear muffs, safety shoes, gloves).

♦ Never place your hands in the work and moving parts zones when the ma-

chine is running.

− danger of injury to the operator

The operator must wear suitable safety equipment!

Caution!



10.2 Changing the blade

• Completely remove the locking screw – 2-,

raise the guard -3- .

• loosen the screws -4- .

• Turn and push the chip remover -5- in the

direction of the arrow away from the blade.

• loosen the hex. bolt -6- and

• screw out.



• extract the thrust flange -7- .

• attach the special hook -8- to the blade as depicted,

• carefully remove the blade from the gearbox journal and lift away with a crane.



The rear stabilisers – 11 - must be checked for wear and replaced, if necessary.

• Fit blade and chip remover in reverse sequence.

When fitting a blade with a different tooth pitch, you must also exchange the

chip remover. Refer to Chapter 9.3.1.

• loosen the locking screws -12-.

• gently adjust the front stabilisers -9- and the rear stabilisers -11- by hand with

the aid of the pressure screws (guard- front side).

Caution!

The stabilisers must only make slight contact with the blade and not exert pressure.

Make sure that the blade does not become misaligned or jammed by the stabilisers. Cor-

rect adjustment ensures square, clean cuts and increases the service life of the blade..

• Retighten the locking screws -12- .



• press key "Secure system".

Lock safety gates.

When the key "Secure system" has been operated, the message „ Press key Tool

Off „ appears. By operating the key „Tool Off „, the spindles will return to their

home positions.

Sawing operations are continued.

Measure the diameter of the blade after completion of the blade change and

enter the actual diameter and thickness in the programming software under # 2

machine data # 5 saw data ( FD software only ).

Make sure, under all circumstances, that the blade is moistened with cooling

emulsion before the first cut is made.



10.3 Chip remover

The chip removing wheels are tuned to the tooth pitch of the individual blades

used.

The standard scope of supply includes a chip remover for Z5 tooth pitch.

Suitable chip removers are available for blades of other tooth pitches.

10.3.1 Changing the chip remover

• Prepare the system for changing the chip

remover as described in Chapter 10.2

“Changing the blade „.

• remove the holder -2- after releasing the

screws -1-

• loosen screws -3-

• pull out chip remover complete with axle -4-

• Fit new chip remover in reverse sequence.



10.3.2 Adjusting the chip remover.

• Prepare the system for adjusting the chip

remover as described in chapter 10.0

„Changing the blade“.

• loosen screws -3-

• Push the remover together with the axle

towards the gearbox to the point where the

remover pins locate in the base of the teeth.

Turn the remover together with the axle to the point where the pins dip into the

blade over its full width.

• tighten screws -3-

The remover must not jam in the blade after it has been adjusted. It must be

easily movable by hand.




The Signomat (OPTION)

11.1 Notes on safety 11 – 2

11.2 Adjustment of the Signomat 11 – 3



11.1 Notes on safety

Please pay specific attention to the notes on safety when operating and working on the

marking system.

♦ Always turn the main disconnect switch off before carrying out any repair,

servicing or maintenance work.

♦ If the system is hooked up to factory supply lines, the system is only to be

put into operation when the point of sourcing is made safe and the prescribed

safety equipment is in place.

♦ The operator must make sure that the system is ready for operation prior to

beginning work ( change of shifts ).

♦ The operator should be equipped with safety gloves, safety shoes, leather

apron and safety glasses. Ear protectors are also recommended.

♦ No mechanical modifications or additions are to be made to the system.

Warning!



11.2 Adjusting the Signomat

The Signomat is controlled by the program and automatically adjusted to the

particular section to be marked.

The Signomat must, however, be manually adjusted to the flange or leg

thickness of the work-piece.



The pass-through aperture of the Signomat is to be adapted to the work-piece by adjust-

ing the counter-holder -2- .

Examples:

- Position of the counter-holder on an I beam

- Position of the counter-holder on I beams and channels up to 120mm

- Position of the counter-holder on angle iron.



The stamping pressure is set on the pressure reducing valve -15-.

Maximum pressure = 150 bars.

The required stamping pressure ( inscription depth ) is adjusted by the pressure switch

-14- . It must be lower than that set on the pressure reducing valve -15- .




MEBA Band Saw (OPTION)

12.0 MEBA Band Saw 560 DG 1000 12 – 2



12.0 MEBA Band Saw 560 DG 1000

You will find the operating instructions for the MEBA band saw 560 DG 1000 in Part 2 of

this manual.




EC Conformity and Manufacturer’s Declarations

13.1 Manufacturer’s declaration of conformity Peddinghaus. 13 – 2



13 EC CONFORMITY AND

MANUFACTURER‘S DECLARATIONS

13.1 EC Declaration of conformity by the manufacturer



13.1 EC Declaration of Conformity

as specified by the EC guidelines

Ξ Machines 98/37 EC, Annex II A

Ξ Electro-magnetic compatibility 89/336/EEC

Ξ Low voltage guidelines 73/23 EG

The machine

Make:

Model:

Flat Bar Drilling and Flame Cutting Machine

Peddimat – FDB 600 / 3

is developed, designed and manufactured in accordance with the EC Guidelines 89/37 EC

under sole responsibility.

Firm: Paul Ferd. Peddinghaus GmbH, D-58285 Gevelsberg, Hasslinghauser Str. 156

The following harmonised standards are applied:

Ξ DIN EN 292-1/2 Machine Safety – Appliances and systems

Ξ DIN EN 294 Safe distances to prevent the upper limbs from reaching pinots of

danger.

Ξ DIN EN 349 Minimum safe distances to prevent crushing of parts of the body

Ξ DIN EN 418 E-stop facilities, functional aspects, design guidelines

Ξ DIN EN 953 General requirements in respect of design and assembly of separating

safety equipment.

Ξ DIN EN 954-1 Safety related parts of controls; general design guidelines

Ξ DIN EN 982 Safety requirements in respect of fluid operated systems and hydrau-

lic components

Ξ DIN EN 983 Safety requirements in respect of fluid operated systems and pneu-

matic components

Ξ DIN EN 1037 Machine Safety – prevention of unintentional start-up

Ξ DIN EN 1050 Machine Safety – risk assessment

Ξ DIN EN 1088 Locking devices with and with follower

Ξ DIN EN 50100-1 Non-contact safety appliances

Ξ DIN EN 50100-2 Non-contact safety appliances with active optical–electrical principle

Ξ pr EN 50081-2 EMC Standard Interference Transmission Industrial Field

Ξ pr EN 50082-2 EMC Standard Interference Resistance Industrial Field

Ξ DIN EN 60204-1 Electrical equipment of machines; general requirements

Ξ prEN 31202 Acoustics, noise radiation by machines

Complete technical documentation is available.

Ξ The appropriate operating instructions manual for the machine is available in

the original version.

ϒ The appropriate operating instructions manual for the machine is available in

the language of the country in which it is in use.

______________________ ______________________ _______________________

Place, Date Signature Details of person signing

Operating Instructions for the Peddimat tandem Saw/Drill line

Peddimat – BDL 1000/9Chapter 2 / 1


Fundamental notes on safety

2.1 Observance of safety instructions in the manual 2 – 2

2.2 Informal safety measures 2 – 2

2.3 Duties of the user and the operator 2 – 2

2.4 Training of operating personnel 2 – 2

2.5 Explanation of hazard symbols, notes and signs 2 – 3

2.6 Personal safety apparel 2 – 3

2.7 Places of work for the operating personnel/ particular danger

zones

2 – 4

2.8 Hazards involved in the operation of the saw/drill line 2 – 4

2.9 Safety measures under normal operation 2 – 4

2.10 Hazards caused by electrical energy 2 – 4

2.11 Hazards caused by hydraulic and pneumatic energy 2 – 5

2.12 Maintenance and servicing , remedying faults 2 – 5

2.13 Mechanical modifications to the system 2 – 5

2.14 Noise levels emitted by the system 2 – 5



2 FUNDAMENTAL NOTES ON SAFETY

2.1 Observance of safety instructions in the manual

The basic requirement for the safe use and trouble-free operation of this machine is full

knowledge of the fundamental safety notes and instructions contained in this manual.

This manual sets forth the most important instructions for operating the machines in a

safe manner. The instructions manual, in particular the safety instructions, must be ob-

served by all persons working on or operating the machines! In addition, the accident

prevention regulations and instructions applicable to the site at which the machine is lo-

cated must also be observed.

2.2 Informal safety measures

The operating instructions manual is always to be kept on site. In addition to the manual,

both the generally applicable and the local accident prevention regulations and environ-

ment protection regulations must also be on site and be observed. All safety and hazard

signs on the machine must be kept in a clearly legible condition.

2.3 Duties of the user and the operator

Only persons are allowed to operate the machine who

♦ are fully acquainted with the fundamental safety and accident prevention regulations

♦ have been fully trained in the operation of the machine

♦ have read and fully understood the chapter on safety and the warning signs

♦ and have confirmed the above by applying their signature.

The user will check the safety conscious operation of the machine by the operating per-

sonnel at regular intervals.

2.4 Training of operating personnel

Only fully trained personnel are allowed to work with the machine. The responsibilities of

the operators is to be clearly stipulated by the user in respect of assembly, start-up,

set-up, checks, operation, maintenance and servicing.

It is the operator’s job to:

− set up the machine for the desired purpose

− set the machine to the desired mode of operation and to secure

against unauthorised readjustment

− set up the required tools

− adjust and check all safety equipment

− check the machines upon completion of set-up

− to operate the machines when they have been set up



2.5 Explanation of hazard symbols, notes and signs

The following symbols and descriptions are used in the manual to denote hazards:

This symbol indicates immediate danger to the life and health of per-

sons.

Non-observance will result in severe damage to health and even cause life

threatening injuries.

This symbol, indicates a possible threat of danger to the life and health

of persons. Non-observance will result in severe damage to health and

even cause life threatening injuries.

This symbol indicates a possible dangerous situation. Non-observance

can lead to slight injury or cause damage to property.

This symbol provides important information on the proper operation of the

machines. Non-observance can lead to faults on the machines or

disturbances in the surrounding area.

♦ This sign indicates a value determined and fixed by the manufacturer.

• This sign indicates a machine reaction subsequent to an actuation.

– This sign indicates that the operator must perform an action.

2.6 Personal safety apparel

When working with the machines, the operating personnel must wear suitable safety

apparel:

The operator must pay particular attention when working with the machines and handling

the work-pieces and the tools to:

− head protection (hard hat)

− finger protection (long gloves)

− protection of the upper limbs (arms)

− protection of the body (leather apron)

− protection of the feet (safety shoes)

• sharp edged work-pieces

− can cut the upper limbs

Wear suitable safety apparel!

Danger!

Warning!

Caution!

Warning!



2.7 Places of work for the operating personnel / particu-

lar danger zones

The operator workplaces are always located outside the machine’s safety equipment

(barriers etc.) in the vicinity of :

♦ the controls

The area in the machine, up to 1m from the tool location, must be considered as being a

particular danger zone. The operator is only allowed to walk in the area inside the safety

fencing to remedy faults under very special conditions.

2.8 Hazards involved in the operation of the saw/drill

line

The Peddimat tandem saw/drill line is built in accordance with state-of-the-art technology

and the recognised safety regulations and standards contained in the EG guidelines.

Nevertheless, hazards to life and limb of the user or third parties or influences affecting

the machines and property can occur during its use. The machines are only to be used:

♦ for their intended purpose

♦ in perfectly safe condition

♦ faults affecting the safe use must be reported to the responsible people and remedied

immediately.

2.9 Safety measures under normal operation

Only operate the machines when all safety equipment is fully functional. Care must be

taken to ensure that, prior to turning on the machines, nobody can be endangered when

they start up. Check the machines at least once every shift for externally recognisable

damage and full functionality of all safety equipment ( refer to Chapter 6.8 Operation).

2.10 Hazards caused by electrical energy

Work on electrical and electronic supply facilities is only to be performed by a qualified

electrician:

− the electrical equipment must be regularly checked.

− the switch cabinet must be kept closed at all times.

− access is only granted to authorised personnel with key or tool.

2.11 Hazards caused by hydraulic and pneumatic energy

Work on the hydraulic / pneumatic equipment is only to be performed by qualified per-

sonnel with special experience in the field of hydraulic/pneumatic and press technology:

− depressurise the sections of the system to be opened and pressures lines prior to

− commencing maintenance work and secure against dropping ( refer to Chapter 9 ).

− replace hydraulic hoses at the prescribed intervals, even when no faults or damage

that could affect safety are apparent (refer to Chapter 9).



2.12 Maintenance and servicing, remedying faults

The prescribed adjustment, maintenance and inspection work must be carried out at the

times stipulated: (refer to Chapter 7)

− operating personnel are to be informed prior to the commencement of maintenance

and service work.

− de-energise the system, lock the main switch and remove the key when all mainte-

nance, inspection and repair work is to be performed

− attach a warning sign to prevent restarting of the machine

− larger assemblies are to be attached to lifting gear and secured when being replaced

− check screw connections that have become loose for tightness

− check the safety equipment and its function after maintenance work has been com-

pleted

2.13 Mechanical modifications to the system

No modifications, conversions or additions to the machines may be made without the

express consent of the manufacturer. This also applies to welding work on components

subject to load and stress.

All modification or conversion work must be confirmed in writing by Messrs. Paul Ferd.

Peddinghaus GmbH.

Components not in perfect condition must be replaced immediately.

Only Original spare parts and consumables may be used.

It is not guaranteed that parts purchased from other sources are properly designed to

cope with stresses and provide the required degree of safety.

2.14 Noise levels emitted by the system

The permanent noise level emitted by the system is ≤ 70 dB (A)

A noise level of 85 dB (A) at the place of work can be exceeded as a result of such

influences as material transport through the machine, sawing and drilling; in this case,

noise protection measures for the operator are compulsory.




Transportation, storage and delivery

3.1 Information and protective measures for transportation 3 – 2

3.2 Delivery of the machines 3 – 2

3.3 Dimensions and weights 3 – 2

3.4 Unloading, loading of the machines and assemblies 3 – 3

3.5 Storage location, duration, protective measures 3 – 4

3.6 Checking scope of supply for damage, missing parts 3 – 4

3.7 Scope of supply 3 – 5

3.8 Notification of defects, damage and/or missing parts upon

receipt of delivery

3 – 6



3 TRANSPORTATION AND DELIVERY

3.1 Information and protective measures in connection

with the transportation of the machine

The various machine assemblies must be safely loaded onto the carrying vehicle ( truck,

wagon ) by means of a crane or forklift truck and secured. Securing can be effected by

means of:

♦ tying chains

♦ tying straps

The dismantled assemblies / machine must be protected against environmental influ-

ences. The following steps should be taken:

− use a suitable cover to protect assemblies/ machine against

dust or dirt.

To avoid damage to the paint, don’t allow straps or chains to rub against

movable parts of the assemblies / machines. Insert rubber shims

between the chains or straps.

3.2 Delivery of the machine

The assemblies/ machine are delivered from the factory in the following manner:

Description Manufacturer Qty. Packed Dismantled

Drilling machine incl. control Peddinghaus 1 no yes

Band saw incl. control console

(option)

MEBA 1 no yes

Circular cold saw LC 1250

(option)

Peddinghaus 1 no yes

Hydralic power-pack BW - Hydraulik 1 no yes

Control Peddinghaus 1 yes yes

Signomat (option) Peddinghaus 1 no yes

In-feed and out-feed conveyors Peddinghaus 1/1 no yes



3.3 Dimensions and weights

Description Dimensions

L x W x H (mm)

Weight (kg) Method of load-

ing

Drilling machine incl. control 2100 x 6100 x 3000 10.000 Crane

Band saw incl. control console

(option)

2600 x 3250 x 2300 3.300 Crane

Circular cold saw LC 1250

(option)

1450 x 3350 x 2400 9.000 Crane

Hydraulic power pack 1100 x 700 x 1150 550 Crane / fork-

lift

Signomat (option) 1400 x 900 x 1700 1100 Crane/forklift

Control 850 x 800 x 1500 300 Crane/forklift

In-feed and out-feed conveyors 12140-24020 x 1590 x

660

depending

on weight

Crane/forklift

3.4 Unloading, loading of the machine and assemblies

The assemblies / machine must be conveyed by a suitable means of unloading (crane /

forklift). Use suitable cables, chains or straps in accordance with the weights for loading

or unloading. (see 3.2). The arrangement of the cables (chains) and the points of at-

tachment to the machine and assemblies can be taken from the drawings.

♦ machine or assembly suddenly falls down

− crushing of persons or parts of the body

It is prohibited for persons to walk or dwell in the danger zone of the

machines or assemblies.

The following points must be observed upon delivery of the machine and assemblies:

♦ only lift the machines or assemblies off the carrying vehicle by means of

crane or forklift truck

♦ unloading and transportation of the machine and assemblies to the erection

site must be carried out by a qualified person with the aid of a crane or fork-

lift truck and, at the same time, observing all safety requirements.

♦ attachment of the cables or chains to the machine components must only be

carried out with shackles or straps ( in accordance with the load ).

Warning!

Warning!



3.5 Storage location, duration, protective measures

If the machines and assemblies are put into storage, attention must be paid to the fol-

lowing points!

Max. period of storage

Longer storage

♦ 1 month

♦ if a period of 1 month is exceeded, a new coating of

preservative must be applied to the assemblies

Protective measures ♦ ensure adequate protection against dust and dirt

♦ the base preservative must not be removed

♦ protect all electrical and electronic parts against

condensation of water.

Ambient temperature ♦ storage not below + 5 C ° to max. 70 % humidity

3.6 Checking the consignment for damage and missing

parts:

The system is to be immediately checked upon delivery for:

♦ visible damage (transportation damage) to the assemblies incl.

accessories

♦ completeness of the consignment.

If damage ( defects ) to the machine are established, or the consignment is incomplete,

direct your claim in writing ( see attached form ) within 1 week to the manufacturer or

supplier.



3.7 Scope of supply

Description Manufacturer Qty.

Drilling machine incl. control Peddinghaus 1

Band saw incl. control console (option) MEBA

Circular cold saw LC 1250 (option) Peddinghaus

Hydraulic power-pack BW Hydraulik 1

Out-feed conveyor (option) Peddinghaus 1

In-feed conveyor (option) Peddinghaus 1

In-feed cross transfer table (option) Peddinghaus 1

Out-feed cross transfer table (option)

Operating materials

Accessories

Technical documentation

Peddinghaus 1

Control Peddinghaus 1

Special accessories:

Description Manufacturer Qty.



3.8 Notification of defects, damage and / or missing

parts

Name of machine :

Machine type :

Year built :

The following q damage, q defects, q missing parts were established on the assem-

blies upon receipt of delivery on.......................................................

Transport damage: q yes q no if yes, indicate nature:

Was the truck driver informed of the damage incurred during transportation?q yes q no

Who established that damage had been incurred? Name:

Which parts and equipment are missing ?

When was the consignment checked for completeness? Date:

Who did the checking? Name: Telephone:

Name and address of the user:

Company : Contact:

Street:

Postal code/town:

Telephone: Facsimile:

Complete the questionnaire and post or fax it to:

Company: Firma Paul Ferd. Peddinghaus GmbH


Fax. + 49 (0) 2332 – 72 208




Technical specifications

4.1 Description, model, serial number 4 – 2

4.2 Technical specifications 4 – 2

4.2.1 Assemblies and machines comprising the system 4 – 2

4.2.2 Overall dimensions 4 – 2

4.2.3 Weights of auxiliary components 4 – 2

4.3 Machine specifications 4 – 2

4.3.1 Overall dimensions 4 – 2

4.3.2 Machine specification 4 – 3

4.3.2 Technical specifications – drilling machine 4 --3

4.3.2 Technical specification – circular cold saw (option) 4 --4

4.3.2 Technical specifications - Signomat 4 --5

4.3.2 Technical specifications – bought-in components 4 --5

4.3.3 Electrical specifications 4 – 6

4.4 Electrical equipment in accordance with VDE 4 – 6

4.5 Climatic conditions on site 4 – 7

4.6. Foundations 4 – 7



4 TECHNICAL SPECIFICATIONS

4.1 Description, model, serial number

Description: Drilling machine BDL 1000/9

Model: Peddimat BDL 1000/9

Serial – No. / Inventory – No.

Year built

4.2 Technical specifications

4.2.1 Assemblies and machines comprising the system

Description Manufacturer Qty

Drilling machine Peddinghaus 1

Hydraulic power-pack BW - Hydraulik 1

Band saw MEBA ( option ) MEBA 1

Circular cold saw LC 1250 ( option ) Peddinghaus

Signomat (option)

Control

Out-feed conveyor (option)

In-feed conveyor (option)

Peddinghaus

Peddinghaus

Peddinghaus

Peddinghaus

1

1

1

4.2.2 Overall dimensions

Unit Dimensions Com.

Overall width mm 6500

Overall length mm 2720

Overall height of the system mm 2900

4.2.3 Weights of the auxiliary components


Signomat

Hydraulic power-pack

kg

kg

1100

550

Out-feed conveyor (option) kg Depends on

length

In-feed conveyor (option) kg

4.3 Machine specifications

4.3.1 Overall dimensions


Overall width of machine mm 2720

Overall length of machine mm 6500

Overall height of machine mm 2900

Weight of machine kg 10000



4.3.2 Machine specifications

4.3.2.1 Drilling machine technical specifications

BDL 1000/9 G

Metric

Max. working width 1000 mm

Max. working height 420 mm

Max. traversing speed in the X-axis 40 m/min

Traversing speed web (Y-axis) 20 m/min

Traversing speed flanges ( Z and W axes) 17 m/min

Work-piece weight Max. 8000 Kg

Measuring range 99,999 m

Total connected load 50 kW

Air consumption / per hour approx. 80 m³/h

Air pressure 6 bars

Control CNC 840 D

Machine dimensions (depth x width x

height)

2720 x 6500 x 2900

mm

Weight approx. 10.000 kg

Number of drill spindles 9

Number of drill spindles per axis 3

Feed rates, program controlled 25 – 300 mm/min

Drill speeds

Spindle 1 from – to min

-1

Program


-1

Program


-1

Program

10 – 580

10 – 395

10 – 580

Drill diameter from – to 8 – 40 mm

Work-piece dimensions

I beams (INP) 80 – 600 mm

I beams (IPE) 80 – 600 mm

Standard channels (UNP) 50 x 25 mm - 400 mm

I beams (HEB) 100 – 1000 mm

I beams (HEA) 100 – 1000 mm

I beams (HEM) 100 – 1000 mm

Angle iron, equal legs

80 x 8 mm

-

200 x 28 mm

Angle iron, unequal legs

80 x 65 x 8 mm

-

250 x 90 x 16 mm



4.3.2.2 Circular cold saw technical specifications (option)

LC 1250

Metric

Max. beam width at 90° 1000 (1250) mm

Max. beam width at 45° 700 (800) mm

Max. beam depth 440 mm

Connected load 20 kW

Air consumption/ per hour 50m³/h

Air pressure 6 bars

Machine dimensions depth x width x height

1450 x 3105 x 2375

mm

Weight (loading and shipping weight incl.

base plate

10.000 kg

Weight not incl. base plate

Blade diameter

8.300 kg

Blade diameter

Kerf

1250 mm

Kerf 9 mm

Cutting speed standard design max. 40 m/min

Cutting speed ( option ) 20 / 40 m/min

Blade feed max. 4 m/min

Blade return speed 6 m/min

Work-piece dimensions

I beams (INP) 80 – 600 mm

I beams (IPE 80 – 600 mm

Standard channels (UNP) 50 x 25 mm - 400 mm

I beams (HEB) 100 – 1000 mm

I beams (HEA) 100 – 1000 mm

I beams (HEM) 100 – 1000 mm

Angle iron, equal legs

80 x 8 mm

-

200 x 28 mm

Angle iron, unequal legs

80 x 65 x 8 mm

-

250 x 90 x 16 mm



Technical specifications – Signomat (option)

Type Signomat 05

Marking speed Seconds per stroke 1.5

Marking pressure kN 0 – 75

Height adjustment – cylinder stroke mm 0 – 650

Marking stroke mm 100

Pass through dimension mm 8 – 165

Machine dimensions approx. Mm 1400 x 900 x 1700

Weight approx. Kg 1200

Workpiece sizes All standard section sizes

processed on the saw/drill line

(angles, channels and I beams)

can be marked.

4.3.2.4 Technical specifications of bought-in components

(Options)

Description Manufacturer Supplier manual

Hydraulic power-pack BW - Hydraulik refer to manual *

CNC control Siemens refer to manual *

Processing software Farm Design refer to manual *

Band saw ( option )

Chip conveyor

MEBA

IFT

refer to manual *

refer to manual *

• Please refer to the separate instructions manuals included in

the scope of supply for the technical specifications of bought-in

components.



4.3.3 Electrical specifications

Unit Value Com.

Connected load kW 55

Type of mains 3 PE 400 V

Control voltage AC/DC V 220 / 24

Fusing max. A 50

4.4 Electrical equipment in accordance with VDE

Enclosed, air conditioned control console with control and power outputs for:

♦ axis drives,

♦ hydraulic pump,

♦ tank heater,

♦ main spindle drive

♦ drill hydraulics

♦ coolant,

♦ clamping hydraulics

♦ E-stop system.

♦ built-in CNC – control using micro-processor technology, Model Sinumerik 840 D from

Siemens

♦ compact unit for logics and operating panel,

♦ control panel with TFT monitor, machine control panel,

♦ RS232 C interface, V 24 or 20 MA, buffered parts programme memory.

♦ system diagnostics and integrated PLC control.

The system is installed by Peddinghaus engineers. It is only to be powered up by a quali-

fied electrician.

Electrical hook-up is to be effected in accordance with the circuit diagrams whereby the

VDE 0100 regulations and the special regulations of the local electricity supply company

are to be observed.

Compare the operating voltage with the available mains supply. The operating voltage of

the machine is stated on a card attached to the switch cabinet. The voltage stated is the

phase-to-phase voltage ( voltage between the phases L1-L2-L3). The phase-to-phase

voltage must not exceed a maximum of VAC + 0%!

Primary fusing and the power supply cable are to be sized and made available by the

user and installed by a qualified electrician in accordance with the layout. In doing so,

the VDE 0100 regulations and the special regulations of the local power supplier must be

observed.

The power supply cable for a connected load of 55 KW (not including optional equipment)

must be installed at the point depicted in the layout and be of sufficient length above the

ground.



4.6 Climatic conditions on site

The following climatic conditions must be maintained in order to guarantee trouble-free

operation of the system:

Ambient temperature: ♦ + 5 C° / + 40 C°

♦ the average air temperature must not exceed + 35° C

over a period of 24 hours.

Humidity: ♦ 30 % to 95 % (non-condensing)

♦ Standard 70

Height: ♦ 1000 m above sea level

4.6 Foundations

The machines and their appropriate material handling system must be placed on a level

foundation and bolted to the floor!

♦ Level concrete flooring with a thickness of at least 200 mm is required. The floor load

is approx. 5 kg / cm

2

.

♦ The depth of the foundations depends on the existing site conditions. The user is re-

sponsible for the installation of the correct foundations. (refer to the foundation draw-

ing in Part 2 of this manual).




Installation, assembly, initial start-up

5.1 Factory site / place of use 5 – 2

5.2 Machine and foundation dimensions 5 – 2

5.3 Erecting the system 5 – 2

5.3.1 Installation and assembly of the machine (A) 5 – 3

5.3.2 Installation and assembly of the hydraulics (B) 5 – 3

5.3.3 Installation and assembly of the conveyors (C) 5 – 4

5.3.4 Installation of the control console (D) 5 – 4

5.3.5 Fitting the safety equipment (E) 5 – 4

5.3.6 Mounting the air supply lines (F) 5 – 4

5.3.7 Fitting the electrical connection cables (G) 5 – 4

5.3.8 Hook-up of the power supply (H) 5 – 5

5.3.9 Cleaning machine components (I) 5 – 5

5.4 Conditions for initial start-up / trial run 5 – 6

5.5 Initial start-up / trial run 5 – 7

5.6 Acceptance protocol 5 – 9



5 INSTALLATION, ASSEMBLY, INITIAL START-UP

5.1 Factory site / place of use

To ensure guaranteed accuracy in conjunction with maximum machine and component

stability, the following conditions must prevail on site:

♦ a level concrete floor, at least 200 mm thick

♦ the floor load capacity must be at least approx. 5 kg/cm

2

(machine weight approx. 10.000 kg)

♦ foundations prepared in accordance with Peddinghaus

specifications

♦ power supply point (connected loads Chapter 4.)

5.2 Machine and foundation dimensions

The machines must be placed on a smooth, level foundation and securely welded

(refer to foundation drawing).

The machine and foundation dimensions are to be taken from the enclosed drawing

5.3 Installing the system

The installation of the system in conjunction with the initial start-up must be carried out by

the manufacturer’s service engineers. ( Chapters 1.3 and 1.5 Fundamental notes ). Please

take all installation dimensions from Chapter 5.

The following installation work must be performed in the sequence indicated:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Installation and assembly of the system

Band saw from Meba

Drilling machine

Signomat (option)

Hydraulic power-pack

Control console

Hoop-up of the power supply

Assembly of the pneumatic and hydraulic connections

Fitting the safety equipment

Cleaning the drilling machine and auxiliary components



5.3.1 Installation and assembly of the machine (A)

I. The following action is required for installing the machine:

1. Attach the lifting cables to the machine’s lifting lugs with

shackles (appropriate to the loads).

2. Lift the machine by crane and place on the foundation.

3. Place machine on foundation.

• machine suddenly sways or drops

− crushing of persons or parts of the body

Do not dwell or walk in the danger zone or under the suspended load!

II. Fixing the machine to the foundations:

♦ in accordance with the manufacturer’s specifications, a solid

connection must be created between the foundations and the

machine.

5.3.2 Installation and assembly of the hydraulics (B)

− place the hydraulic power-pack, using suitable lifting gear

( crane/forklift truck ) on its location and install

− install the hydraulic piping

• components suddenly drop down

− crushing of persons and parts of the body


The hydraulic power-pack is supplied without fluid! The following points must be

observed when filling the machine with hydraulic fluid:

Chapter. 9.7.2 > − only use the prescribed hydraulic fluid (Chapter.9.7.2)

− use a filter when filling

− close the filler cap tightly when filling completed

The following work is required for this purpose:

Chapter. 9.7.4 > − Remove the filler cap

− Pour in hydraulic fluid up to 1 cm below the max. level

(observation glass)

− Replace filler cap

− Absorb and dispose of spilt fluid immediately (danger of

slippery floor surface)!

The oil level is to be checked after a test run and replenished, if neces-

sary!

Warning!

Warning!

Caution!



5.3.3 Installation and assembly of the conveyors (C)

− place the conveyors on the in-feed and out-feed sides in

position with the aid of suitable lifting gear ( crane/forklift

truck ) and assemble




5.3.4 Installation of the control console (D)

Assembly work: − Place the console in position with the aid of suitable lifting gear

(crane/forklift truck) and fix in position

− install the electric cables to the machine and the components




5.3.5 Fitting the safety equipment (E)

Position the guards and safety equipment and assemble.

5.3.6 Mounting the air supply lines (F)

Fitting: − assemble the air supply lines on site

− the supply pressure must be 6 bars

− only use dry compressed air

− check lines and connections for leakage

5.3.7 Fitting the electrical connection cables (G)

• electrical energy

This work is only to be carried out by a qualified electrician ( refer to

Chapter 2.10)

Installation work:− install all electrical connection cables from the console to he

machine, components and operating controls.

Warning!

Warning!

Caution!



5.3.8 Hook-up of the power supply (H)

• Electric power

Hook-up is only to be carried out by a qualified electrician (refer to

Chapter 2.10)

− Connect the terminals L1, L2, L3, PE in the switch cabinets to

the power point 3 PE 400V 50 Hz. (refer to Chapter 4 for

connected loads)

When the machine has been connected up to the power supply, the

direction of rotation of the drive motors must be checked and corrected,

if necessary.

5.3.9 Cleaning machine components (I)

All components of the machine protected by anti-corrosive :

− guides

− tool chucks

− etc.

must be cleaned with a suitable solvent or cleaning agent (refer to manufacturer’s

instructions in respect of the solvent/cleaning agent to be used).

Pay attention to the applicable regulations when disposing of the

solvent (waste disposal act)!

Caution!



5.4 Conditions for initial start-up / trial run

Conditions: − the service personnel must be fully acquainted with the

machines and know how to handle them.

The following instructions on safety must be observed under all circumstances prior to

turning the machine on!

On site prior to powering up:

Checks must be made to ensure that:

♦ all documentation i.e. operating instructions manuals, electrical, hydraulic,

pneumatic circuit diagrams, technical drawings or testing equipment etc. are

available.

♦ all guards and safety equipment are in place and no unprotected danger

zones exist in the areas of access.

Start-up:

The checks must also verify that the following points coincide with the ap-

plicable sections of the safety standards:

♦ that separation/connection of the power supply and the normal stopping and

starting of the machine function properly.

♦ that acoustic and visible warning facilities function properly.

♦ that speeds and areas of movement of all movable components are in line

with specifications and that all limit switches and E-stops operate properly

when actuated.

Faults incurred during installation/assembly:

♦ It can happen, as a result of incomplete assembly of various components,

that during the installation process and at start-up, hazards of varying nature

occur.

♦ The person responsible for installation and start-up must carefully study the

requirements set forth in the instructions on machine installation and ensure

that such requirements are met and all safety instructions fully applied..

Overview of the control and display elements as well as the fault indicators;

refer to Chapter 6.2

Warning!

Warning!

Warning!



5.5 Initial start-up / trial run

The installation and start-up personnel must carry out the following work:

Procedures 1 - 21 1. Turn main switch to position ON

• the CNC control will be turned on.

Chapter. 6.3.2.1 > 2. Perform visual check of all safety equipment

3. Press key „ Control ON „ on the control console

• the hydraulics are turned on

• wait for approx. 10 seconds until the display “Pressure

build-up please wait” extinguishes.

The LED lamp above the key lights up

4. Press key „ Secure system”

Chapter. 6.3.3.2 > 5. Check E-stop by:

− pressing E-stop

• the hydraulic system will be turned off

• The message „ E-stop pressed“ will appear on the

control display.

• E-stop malfunction


If the functional test cannot be performed as described, immediately

turn off the machine and notify the manufacturer’s customer service

department!

6. Unlock E-stop

7. Press key „ Control ON „


hydraulics are turned on

8. Press key “ secure system „

• control voltage, the error message on the control display

extinguishes

Chapter. 6.3.2.2 >

Chapter. 6.3.2.3 >

9. Make functional check of safety switches on the safety gates

or

− conduct a visual and functional check of the safety light barrier

(optional)

Chapter. 6.5 > 10.Carry out adjustments and checks

Chapter. 6.6 > 11.Turn on the peripheral components ( conveyors )

12.Press key „ Spindle start „

• the main spindle drives are activated

13.Press key „ Tool automatic „

• the tool call-ups are activated automatically in line with the

programme

Warning!



14.Press key „ Coolant ON „

• the coolant feed is enabled

The system is ready for operation.

15. Conduct a test run of the system.

The following action is to be taken when the prescribed system quality has been

achieved and no faults detected:

16. Check function of all safety equipment and record in the

acceptance protocol.

17. Train and instruct all operators on the system ( hand-over )

Chapter. 6.8 > 18. Turn the system off



5.6 Acceptance Protocol

Name and address of user:

Company: ______________________________ Street:________________________

Postal code/Town:

_______________________________________________________________

Name of system:__________________________________ Model: __________

Serial No.: ______________________________ Year built: _________

Name of the service and training engineer:_____________________________________

Name of the tester/user: ________________________________________________

System started up on : _ _________________________________

Check of operating and safety equipment performed as per Chapter. 5.5 / 19 on:

________________________________________

Training on the machine carried out on: ______________ Duration: _______________

Machine handed over on:__________________________________________________

Names of operators trained: ____________________________________________

_______________________________________________________________________

The operators trained on the machine confirm the requirements set forth in Chapter 2,

section 2.3 by the manufacturer by applying their signature.

_______________________________________________________________________

_______________________________________________________________________

Signature(s)

The machine was handed over in proper operational condition.

__________ __________________

Date Signature

The machine was handed over in proper operational condition.

_____________ ___________________

Date Stamp / Signature

Operating Instructions for the Peddimat tandem Saw/drill Line

Peddimat –BDL 1000/9 Chapter 6 / 1


Operating the machine

6.1 Introduction 6 – 3

6.2 Operating and display controls, fault messages 6 – 4

6.2.1 The Siemens control 840 D 6 – 4

6.2.2 Controls on the control console 6 – 5

6.3 The safety equipment 6 – 8

6.3.1 Guards, safety fence with safety gates, light barrier 6 – 8

6.3.1.1 The guards on the machines 6 – 8

6.3.1.2 Safety fence with gates 6 – 9

6.3.1.3 The safety light barrier 6 – 9

6.3.2 Checking the guards, the safety fence with gates

and light barrier

6 – 9

6.3.2.1 Visual check 6 – 9

6.3.2.2 Functional check of the safety switches on

the safety gates

6 – 10

6.3.2.3 Visual and functional check of the safety

light barrier ( option )

6 - 10

6.3.3 E-stop facilities 6 – 11

6.3.3.1 Operating the E-stop on the system 6 – 11

6.3.3.2 Functional check of the E-stop facility 6 – 11

6.3.3.3 Restarting the system after E-stop 6 – 11

6.4 Mode of operation and work-cycle 6 – 12

6.4.1 Automatic operation 6 – 12

6.5 Adjustments and checks prior to commencing work

operations

6 – 13

6.5.1 Checking the pressure of the clamping and

measuring rolls

6 – 13

6.5.2 Checking the hold-down / adjustment 6 – 13

6.5.3 Checking the drill assemblies

6.5.3.1 All tools in place

6.5.3.2 Drill rates of feed

6.5.3.3 Changing the drill bits

6 – 14

6 - 14

6– 14

6 - 15

6.6

6.7

Instructions for checking, adjusting and switching on the

system

Turning off the system on normal operation

6 – 16

6 – 17

6.8 Restarting the machine after a power failure 6 – 17

6.9 Instructions for switching individual modules on/off 6 – 18



6.10

6.9.1 Switching the band saw on/off (option)

6.9.2 Switching the circular cold saw on/off (option)

Loading / unloading the machines

6 – 18

6– 18

6.11 Disposal of swarf/chips 6 – 19

6.12 Checking the coolant system 6 – 19

6.13 Replenishing lubricating coolant 6 – 20

6.14 Regulating the amount of coolant 6 – 21

6.15 Maintenance instructions for the operator

6.15.1 Maintenance instructions for the drilling machine

6.15.2 Maintenance instructions for the band saw ( option )

6.15.3 Maintenance instructions for the circular cold saw

( option )

6 – 21

6 – 22

6 – 22

6 - 22

6.16 List of addresses

6.16.1 Addresses for manual data input

6 – 23

6 – 23

6.17 Error messages 6 – 26

6.18

6.19

6.17.1 BDL error messages

Trouble shooting

6.18.1 No drill call-up

6.18.2 No axis movement ( Y,Z,W and Q on the drill, U and

V on Signomat and saw )

6.18.3 No X-axis movement

Summarised operating instructions

6.19.1 Turning the system on

6.19.2 Jog mode

MDA mode

6.19.4 Loading programmes

6.19.5 Deleting programmes

6.19.6 Deleting a programme

6.19.7 Deleting several programmes

6.19.8 Processing parts programmes

6.19.9 Single part output( FD software only )

6.19.10 Manual entry of a programme

6 – 26

6 – 27

6 – 27

6 – 28

6 – 28

6 – 29

6 – 29

6 – 30

6 – 31

6 – 32

6 – 33

6 – 33

6 – 33

6 – 34

6 – 35

6 - 36



6 OPERATING THE MACHINE

6.1 Introduction

This instructions manual is thought for technically, specially trained and qualified person-

nel or personnel with expert knowledge in the field of NC technology.

Full knowledge and technically perfect implementation of the safety instructions and warnings

are prerequisites for non-hazardous operation.

Only qualified personnel have the necessary expert knowledge to correctly interpret and im-

plement the safety instructions and warnings provided in the generally accepted manner.



6.2 Operating and display controls, fault messages

6.2.1 The Siemens control 840 D

X Y Z

- Rapid +

WCS MCS

Tool

Automatic

Drill

Hold Down 1

On

Drill

Hold Down 2

Off

Drill

Coolant

On

Laserpointer

Tool

Test

Tool

Mark

Tool

Off

Saw

Trim Cut

On

Saw

Inital

Setting

Y-Z-W

Automatic

On

Control

Off

Inspect

Plant

Control

On

Protect

Plant

Funktionstasten Achsanwahltasten

V

WQ U

Sprayer

A



6.2.2 Controls on the control console

No Description Function

1 E-stop ♦ Turns off the machine in case of hazard or fault

• The key locks automatically

− Unlock by turning in the direction of the arrow

2 Automatic tool control • Tool call-ups effected as per programme

3 Hold-down 1 • Hold-down 1 active

4 Hold-down 2 • Hold-down 2 active

5 Tool OFF • Tool call-ups not executed. Drilling, marking , saw-

ing operations not executed.

• Tool command interrupted

6 Coolant ON/OFF • Internal coolant supply turned ON/OFF

7 YZW automatic mode ON • Stand-off automatic mode ON/OFF

8 Tool mark • The drills pop mark

9 Trim cut • Trim cut active/inactive

10 Saw home position • Saw frame traverses to topmost position.

11 Tool test Drill spindles briefly extend from the home position

12 Enter danger zone The system functions are turned off in a controlled

manner.

* The safety gates unlocked

13 Secure system • The safety gates are locked

14 Laser pointer • Turn laser pointer for manual saw cut on ( only

applies to the MEBA band saw )

15 Control ON • Hydraulic system turned on

16 Control OFF • Hydraulic system turned off

* CNC control remains on

For description of keys 14 – 20, refer to the SIEMENS operating manual.

17 Select X-axis • X-axis activated

18 Select Y-axis • Y-axis activated

19 Select Z-axis • Z-axis activated

20 Select W-axis • W-axis activated



21

22

23

24

25

26

27

Select Q-axis

Select U-axis

Select A-axis

Saw spray oil

Clamp saw

WCS/MCS

- key

• Q-axis activated

• U-axis activated

* A-axis activated

* Cooling lubricant for band saw ON

* Horizontal vice is opened in sawing cycle

* Switch-over key „drill axis/linear axis“

* The axis selected is traversed in the minus

direction

28 Rapid • Rapid key. The axes are traversed at rapid speed

when the “RAPID” key is pressed in conjunction

with the plus or minus key

29 + key • The axis selected is traversed in the + direction

30 Main switch ON/OFF ♦ Switch position ON

• system is supplied with current

• the CNC control is switched on

υ Switch position OFF

• the system is de-energised

the hydraulic tank heater remains on

can only be turned off using the DO-Q 22 switch

( in the power section )

Attention!

Press the “EXIT” key on the computer keyboard

before tuning off the main switch. The computer is

run down. Only turn off the main switch when the

message “Computer is now safe. Restart”

appears on the screen.

31 E-Stop • Turns off the complete system in case of hazard or

a fault.

• The key is self-locking

* Turn in direction of arrow to unlock

32 Jog ♦ Manual traversing of the axes

33 Teach-in ♦ This key is not

used

34 MDA • Manual data input

35 Auto • Automatic run-off on parts programmes

Attention:

Parts programmes can only be managed with the

control turned on and in automatic mode!

36 Reset (red) Reset key: delete errors, reset control, interrupt

parts programmes

37 Single block Single block key: running off a parts programme

block for block



38 Cycle stop ( red ) Programme stop key

39 Cycle start Programme start key

40 Potentiometer spindle speed υ Potentiometer spindle speed override

Speed change of 50% - 120% of the value

specified in the part programme

41 Potentiometer spindle feed Potentiometer % of axis feed

42 Spindle stop ( red ) υ Main spindle drive stop

43 Spindle start (green) υ Main spindle drive start

44 Feed stop ( red ) υ Axis feed stop

45 Feed start ( green ) υ Axis feed start

46 Key switch Green key:

The green key is only for service purposes

Orange key:

the orange key is only to be used by authorised per-

sonnel

Attention!

Improper use can lead to all data being erased.

COMPLETE MACHINE STANDSTILL

Black key:

The black key should always be in the “1” position.

Key position “0” = data only displayed.

Key position “1” = load or delete data:



6.3 The safety equipment

The machine is guarded at the particular points of hazard by safety equipment.

The equipment is as

follows:

♦ Guards, safety barrier ( fence ) with safety gates

♦ Safety light barrier (Option)

♦ E-stops ( buttons)

6.3.1 Guards, safety fence with gates, light barrier

6.3.1.1 The guards on each machine

Hazard caused by: − unintentional/intentional contact with movable parts during

operation

Prevention: ♦ by rigidly bolted guards at the points of danger

6.3.1.2 Safety fence with gates

Hazard caused by: − unintentional / intentional intervention in the work-cycle of the

machine during operation

− unintentional / intentional entry into the inner danger zone

( inside the safety fence ) when the machine is in operation

Prevention: ♦ a solid, fully closed off protective area around the whole of the

system including safety gates secured by protective switches

Function: ♦ all safety gates must be closed when operating in “automatic”

mode

♦ The safety gates must be locked by pressing key„ Secure

system„

I the event that a safety gate is to be opened during „Automatic“ mode , the following action

is to be taken:

Function: − Press key „ Enter danger zone „ on the control console

• the system functions are turned off in a controlled manner



− the operator is able to enter the inner area of the machine

The system remains turned off when the safety gate is closed until the following action is

taken:

Action: − Press key „ Secure system „ on the control console

• the safety gate will be locked


− the machine can now be restarted



6.3.1.3 The safety light barrier

The system can be equipped with a non-contact safety appliance in the form of a light barrier

(AOS), which protects the whole area surrounding the tools.

Hazard caused by: − unintentional / intentional intervention in the work-cycle of the

machine during operation

− unintentional / intentional entry into the inner danger zone

(inside the safety fence) when the machine is in operation

Prevention: ♦ by installing a non-contact safety device in the form of a light

barrier which protects the whole area surrounding the tools

Components: ♦ transmitter ♦ receiver

Significance of the signal lamps on the light barrier

Signal lamps Function Effect

green • lights up ♦ The protected area is active

yellow • flashes ♦ Fault in system

green • flashes ♦ Contaminated or misadjusted

red • flashes ♦ The protected is interrupted

Function: ♦ the light barrier is constantly active

If the protected area is interrupted during operation:

Function: • all movements of the system are turned off in a controlled

manner

• the red signal lamp lights up (protected area interripted)

Restarting the machine after an interruption:

Function: − Press acknowledge key „ Light barrier active „


• the green signal lamp light up (protected area active)

− the system can now be restarted

6.3.2 Checking the guards, the safety fence with gates and the light

barrier

A check of the guards, the safety fence, the safety gates and the light barrier must be carried

out prior to turning on the machine.

6.3.2.1 Visual check

Action: − check for tightness

− check for damage

− the safety gates must be closed



6.3.2.2 Functional check of the safety switches on the safety gates

Conditions:

Control ON>

♦ Main switch turned on

♦ Control voltage turned on

• The LED lamp is on

Action: − check all safety gates (open and close) and make sure that

nobody is in the inner danger zone ( inside the fence )

− press key „ Secure system „


♦ the safety switches operate properly!

• malfunction of a safety switch


If the functional test cannot be carried out as described, immediately

turn the machine off and notify the manufacturer’s service personnel!

Chapter 6.7 > − for further action refer to Chapter 6.7

6.3.2.3 Visual and functional check of the safety light barrier (op-

tional)

I. Visual check

Action: 1 - 4 1. Check transmitter and receiver for tightness

2. Check transmitter and receiver for cleanliness and damage

3. Check whether access to the hazardous machine movements is

possible from an area that is not protected by the light barrier

4. Check whether the minimum distance between the area of

hazardous machine movements to the light barrier has been

maintained (compare with info on the nameplate)

II. Functional check

− Placing of the test object of suitable diameter in the protected area.

− The test object should be moved down very slowly at three different points; in the

vicinity of the transmitter/ receiver and at the centre of the protective area.

• The indicator lamp that indicates the interruption of the protected area should change

when the test object enters the protected area or leaves it.

• When the test object is in the protected area, its status should not alter in any way

during the whole period.

• malfunction of the components



turn off the machine and notify the manufacturer’s service personnel!

Warning!

Warning!



6.3.3 E-stop facilities

The system is equipped with several E-stops:

♦ Button 1 on the control console

♦ Button 2 at the most dangerous points of the system

If an immediate threat of danger to the operator, the machine or to the material occurs, all

machine functions can be immediately stopped by pressing the E-stop.

6.3.3.1 Operating the E-stop on the system

If an E-stop on the system is operated, the following machine functions are immediately

turned off:

• Control voltage and hydraulics

• The message „ E-stop operated“ appears on the control

display

• The work-cycle is immediately interrupted

The impending danger or the fault in the system must be investigated

and cleared after an E-stop has been operated.

6.3.3.2 Functional check of the E-stop facilities

A check of all E-stop facilities must be made in accordance with Chapter 6.3.3.1 prior to the

machine being turned on!

• malfunction of an E-stop

− danger of injury to the operator’s upper and lower limbs


turn off the machine and notify the manufacturer’s service personnel!

6.3.3.3 Restarting the machine after an E-stop

The following steps must be taken to restart the machine:

Action: − unlock the E-stop

− press key „ Control ON „



- press key “Secure system”

- * the control voltage is enabled


- restart the work-cycle ( programme )

Refer to the separate instructions manual issued by Siemens for restarting the

programme!

Warning!

Caution!



6.4 Mode of operation and work-cycle

Virtually all structural steel sections can be drilled, pop marked, sawn and marked on the

Peddimat tandem saw drill line.

The machine only operates in „Automatic“ mode.

Work operations:

− place the work-piece on the in-feed conveyor and start the

programme by pressing the cycle start key.

Start the system

• the work-piece is now drilled and sawn in accordance with

the programme called up and then discharged automatically

onto the out-feed conveyor.

− the finished work-piece can now be removed from the out-feed

conveyor

6.4.1 Automatic operation

The following conditions must be fulfilled before the machine can be started in „automatic“

mode:

− all adjustments and checks must have been performed.

− the machine itself must have been checked.

− the work-piece must be resting on the in-feed conveyor.

When all conditions for automatic operation have been created, the machine can be started:

Starting automatic

operation:

− press key „ Cycle Start „


• the work-cycle is initiated

Attention:

Take note of the display on the screen (e.g. trim cut yes/no)

Automatic hold: − press key „ Cycle stop „


• the work-cycle is interrupted

Attention:

Drilling operations are not interrupted, the axes do not stop

immediately but complete the value specified in the data block

first.



6.5 Adjustments and checks prior to commencing work operations

The following adjustments and checks must be made prior to the machine going into produc-

tion:

Chapter. 6.5.1 >

Chapter. 6.5.2 >

Chapter. 6.5.3 >

− check pressure of the clamping and measuring rolls.

− check and position the hold-down.

− check the drill assemblies.

6.5.1 Checking the pressure of the clamping and measuring rolls

♦ Check the pressure of the clamping and measuring rolls.

The required clamping pressure depends on the weight and

thickness of the material and is between 25 and 70 bars.

The pressure can always be measured!

6.5.2 Checking the hold-down / adjustment

Check to make sure that the hold-down is at the correct height in relation to the work-piece.

Conditions:

Control ON

♦ Main switch turned on

♦ Control voltage on

• the LED lamp lights up

Action: − press key „ Enter danger zone „ on the control console




− open the safety gate

− loosen the lever –1- and set the roller to the appropriate sec-

tion width

- close the safety gate

− press key „ Secure system „ on the control console





6.5.3 Checking the drill assemblies

The following checks must be made on the drill assemblies:

Chapter 6.5.3..1 >

Chapter 7.6>

− All tools (drill bits) in place

− Check for correct grinding of the drill bits

The drill speeds are specified by the programme and can be adjusted by the

operator on the rotary potentiometer Spindle Override”

6.5.3.1 All tools in place

The data pertinent to the drill bits fitted must coincide with those shown on the control display.

Change the drills, if necessary (refer to Chapter 6.5.3.3)

6.5.3.2 Adjusting the drill rates of feed

The drill feed rates are set by the parts program.



6.5.3.3 Changing the drill bits

Change the drill bits in the following manner:

Conditions:

Control ON

♦ Main switch on

♦ Control voltage on

• the LED lamp lights up

Action - Press key „Enter danger zone“ on the control console

* the safety gate is unlocked and released

- open safety gate

- knock the drill out of the spindle with a drift

- clean the taper

- fit new drill and knock gently using an aluminium hammer

- close the safety gate

- press the key „Secure system“ on the control console

* the safety gate is locked

* the LED above the key lights up

To prevent a newly ground drill from breaking, the cutting edges must be

sharpened (whet) by hand with grinding stone.



6.6 Instructions for checking, adjusting and switching on

the system

Checking and switching on of the system is only to be carried out by an experienced, trained

and authorised operator!

Conditions: ♦ all E-stops are unlocked

♦ the pneumatics are operating

Work operations

1 - 15

Chapter 6.15

1. Carry out maintenance work prior to operation

2. Set main switch to ON

• the CNC control is turned on

Chapter 6.3.2.1 > 3. Carry out a visual check of the safety equipment

4. Press key „ Control ON „ on control console



Chapter 6.3.3.2 > 5 Check E-stop by pressing it

• control and hydraulics will be switched off

• the message „ E-stop operated“ appears on the

control display.

• E-stop malfunction



turn off the system and notify the manufacturer’s service personnel!

6. Unlock E-stop

7. Press key „ Control ON „



• the error message on the control display extinguishes.

Warning!



Chapter 6.3.2.2 >

Chapter 6.3.2.3 >

9. Carry out check of switches on the safety gates

or

− carry out a check of the light barrier (option)

Chapter 6.5 > 10.Perform adjustment work and checks

Chapter 6.9 > 11.Switch on the handling system

12.Press key „ Tool automatic „

* the tools are called up automatically by the programme

13.Press key “Coolant ON”

* the coolant supply is turned on

14.Press key „ Hold-down ON“ „

• the higher ranking selection of the hold-down is active

15.Press key “Y,Z, W Auto ON”

The system is ready for operation

6.7 Switching off the system in normal operating mode

Switch off the system at the end of a shift in the following manner.

Work operations:1- 6 when the programme has been completed:

1. Press key „Enter danger zone„

2. Press key „Control OFF“


• the LED lamp above the key 16 extinguishes

• the hydraulics are turned off

3. Press the softkey “EXIT” on the screen

• the MMC runs down

* The message „ Computer is safe, now restart?“

4. Turn off main switch and lock

5. Shut off the compressed air supply

6. Switch off the material handling system

6.8 Restarting the system after a power failure

When the system is turned off as a result of a power failure

• all system movements are turned off

The following work operations are necessary to restart the system when the power is restored:

Work operations:

Chapter 6.9 > 1. Carry out work operations 4 – 10 / 12 – 15.



6.9 Instructions for switching individual modules on/off

Modules can be optionally attached to the system, or operate in conjunction with the system,

which must, however, be switched on and off separately.

6.9.1 Switching the band saw on/off (option)

The band saw must be checked and switched on/off in accordance with the instructions con-

tained in manufacturer’s manual.

6.9.2 Switching the circular cold saw on/off

The circular cold saw must be checked and switched on/off in accordance with the instructions

contained in the manufacturer's manual.

6.10 Loading / unloading

The system is manually loaded and unloaded.

Loading: − place the section to be processed on the in-feed conveyor and

feed it, using the joystick, into hat system.

Unloading: − the section can be removed from the out-feed conveyor upon

completion of processing.

• sharp edged, coolant residues


The operator must wear suitable safety apparel!

• work-piece falls downs during loading or unloading operations

• danger of injury to the operator

In the case of heavy work-pieces, loading or unloading must be carried

out with the aid of suitable lifting gear!

Caution!

Caution!



6.11 Disposal of swarf/chips

The interior of the machine must be regularly cleaned with a brush.

• chips/swarf, coolant residues


The operator must wear suitable safety apparel!

Action: − Press key „ Enter danger zone „ on control console

• the machine functions are turned off in a controlled manner



− use hand brush to remove swarf and chips from the interior





Observe the pertinent regulations when disposing of swarf/chips (waste disposal

act).

6.12 Checking the coolant system

The coolant system must be regularly checked for leaks, damage and coolant level.

Caution!



6.13 Replenishing cooling lubricant

The machine is equipped with a cooling lubricant reservoir which must always be full.

The reservoir has a capacity of 1 litre spray oil.

We recommend bio spray oil HP 42.

The reservoir is filled as follows:





− open safety gate

- pour in spray oil (refer to instructions manual

HP Microspray II)






Check coolant level several times daily and replenish, if necessary.



6.14 Regulating the coolant flow

The coolant unit delivers drips of coolant automatically, which are atomised by the flow of air.

The mixture of air and coolant is set at the factory and normally needs not to be

changed.






− adjust micro dosing unit (refer to instructions manual HP

Micro spray II)


− Press key „ Secure system „ on control console






6.15 Maintenance instructions for the operator

6.15.1 Maintenance instructions for the drilling machine

Working hours

(h) or intervals

Points to be checked/ maintenance instruc-

tions

Materials

8 / daily

Chap. 9.7.3 / 9.7.4

>

Chap. 6.12 / 6.13 >

Chap. 7.7 >

− Check the pneumatic pressure on the cooling sys-

tem (max. 6 bars)

− Check for cleanliness, clean if necessary

− Check fluid level in the hydraulics and replenish, if

necessary

− Check coolant level

− Check condition of drill bits and regrind, or re-

place, if necessary

Hydraulic

fluid

Spray oil

40 / weekly

Chap. 9.5.1 >

Chap. 9.6 >

− Check oil level in drill assembly and replenish, if

necessary. Grease machine components

BP GR-XP

gearbox oil

Roller bear-

ing grease.

6.15.2 Maintenance instructions for the band saw

(option )

Maintenance instructions for the saw are to be found in the MEBA handbook.

6.15.3 Maintenance instructions for the circular cold saw

(option)

Maintenance instructions for the circular cold saw are to be found in this

manual in sections 10.1 – 10.3.2



6.16 List of addresses

6.16.1 Addresses for manual data input

By entering addresses, the clamping, sawing, Signoscript, Signomat and drilling functions can

be called up one by one.

M address Function

Clamping

functions:

M 22 clamp in-feed side/hold-down down in-feed side

M 23 release in-feed side/hold-down up in-feed side

M 24 clamp/hold-down down out-feed side

M 25 release out-feed side/hold-down up out-feed side

M 26 activate clamps 1 and 3

M 27 deactivate clamps 1 and 3

M 28 activate clamps 2 and 4

M 29 deactivate clamps 2 and 4

Circular cold saw

functions

M 40 saw slow speed on trim cut ON

M 41 saw fast speed on trim cut ON

M 42 saw slow speed

M 43 saw fast speed

M 44 saw OFF

Band saw func-

tions (option)

M 40 trim cut ON

M 41 saw cut

M 44/M30 saw blade home position

Signoscript

functions (option)

M 45 turn Signoscript on

M 46 turn Signoscript off

Signomat functions

(option)

M 145 Signomat: marking operation

M 146 Signomat: traverse Signomat up



M address Function

Drilling functions M 51 Spindle Y1 drilling

M 52 Spindle Y2 drilling

M 53 Spindle Y3 drilling

M54 Spindle Y1 pop marking



M57 Deselect valves for drilling function Y/activate valves for Y

tapping function

M58 Activate valves for Y drilling function / deselect valves for Y

tapping function

M59 Spindle Y1 advance with no rotation

M61 Spindle Z1 drilling



M64 Spindle Z1 pop marking



M67 Deselect valves for drilling function Z/activate valves for

tapping function Z

M68 Activate valves for drilling function Z/ deselect valves for

tapping function Z

M69 Spindle Z1 advance with no rotation

M71 Spindle W1 drilling



M74 Spindle W1 pop marking



M77 Deselect valves for drilling function W/activate valves for

tapping function W

M78 Activate valves for drilling function W/deselect valves for

tapping function W

M79 Spindle W1 advance with no rotation

The spindle speed and the direction of rotation as well

as the individual rapid feed/feed rates must be entered

for the drill addresses.



Example of a complete drill call-up:

Drilling with spindle Y3 at a speed of 250 r.p.m.:

♦ M1 = 3 S1 = 250 * enable spindle with clockwise rotation and a speed of 250 r.p.m.

♦ M53 M1 = 100 * drilling with spindle 3 at rapid feed

♦ M1 = 195 * feed

♦ M5 * turn spindle off

M address Function

Diverse functions M 81 Adjust height of clamping rolls to the dimension set in the

R41 parameter ( in mm ).

M 88 Web sensing activation

M 90 Activate X-axis zero reference lever

M 91 Activate X-axis zero reference bar

M 95 Measuring system switch-over completed

M 96 Switch over measuring system

M 97 Activate measuring system on in-feed side

M 98 Activate measuring system on out-feed side

M 300 Chip conveyor TDK permanently ON

M 301 Chip conveyor TDK permanently OFF

M 302 Chip conveyor saw permanently ON

M 303 Chip conveyor saw permanently OFF

M 94 Activate in-feed encoder

M 999 Reduce piece counter by one

Address Function

Sub-programme

function

L 24 Activate encoder on out-feed side

L 25 Activate encoder on in-feed side

L 74 Travel to X-axis zero reference point

S_Measuring Web probes

PH_Measuring Measure section depth



6.17 Error messages

6.17.1 BDL – Error messages

Error number Description

700032 0 0 NC fault

700033 0 0 Fault E/R module (=G1-A11)

700034 0 0 Watchdog module (=G1-A21)“

700035 0 0 Fault on chip conveyor saw

700036 0 0 Fault on saw motor

700037 0 0 No oil on drill hydraulics

700038 0 0 Oil filter contaminated on drill hydraulics

700039 0 0 Piece counter in excess of 999

700040 0 0 Saw option LC 1000 missing“

700041 0 0 Saw option LC 1250 missing

700042 0 0 No air

700043 0 0 Pressure build-up time for hydraulics, please wait

700044 0 0 Secure system

700045 0 0 Quantity reached, select new programme

700046 0 0 Clamp roll height adjustment on in-feed side in end limit

700047 0 0 Clamp roll height adjustment on out-feed side in end limit

700048 0 0 Fault on extraneous ventilator spindle Y (=H1-Q12)

700049 0 0 Fault on extraneous ventilator spindle Z (=H2-Q12)

700050 0 0 Fault on extraneous ventilator spindle W (=H3-Q12)

700051 0 0 Fault hydraulic motor drilling machine (=E1-Q12)

700052 0 0 Drilling function call up with no programmed speed or spindle. Hold on

the machine control panel is active.

700053 0 0 No coolant

700054 0 0 Web probing active

700055 0 0 Saw horizontal vice reached

700056 0 0 Option Signoscript/Signomat missing

700057 0 0 Option tapping/countersinking on Y-axis drill assembly missing

700058 0 0 Option tapping/countersinking on Z-axis drill assembly missing

700059 0 0 Option tapping/countersinking on W-axis drill assembly missing

700060 0 0 V saw axis not in home position

700061 0 0 Fault clamping roll height adjustment (=E2-Q12, = E3-Q12)”

700062 0 0 Fault on air conditioners (=D0-Q31,=D0-Q32)”

700063 0 0 Plus end limit X-axis on Signomat reached

700140 0 0 Minus end limit Signomat reached”

700141 0 0 Fault chip conveyor drilling machine (=E8-Q12)

700142 0 0 Fault tank heater drilling machine (=DO-Q22)

700143 0 0 Fault tank heater band saw (=D0-Q23)

700144 0 0 Fault control voltage 230V (=D0-Q33)”

700145 0 0 Encoder switch-over activated with clamps open

700146 0 0 X-axis encoder not switched over to clamp

700148 0 0 Saw blockage monitor has responded

700149 0 0 Over-current saw hydraulic motor ( =E5-Q12)

700150 0 0 Fault saw motor (=E4-U11)

700151 0 0 Over-current saw – chip conveyor (=E7-Q12)

700152 0 0 Over-current saw – coolant pump (=E6-Q12)

700153 0 0 Saw home position not reached

700154 0 0 Measuring system clamping block inactive

700155 0 0 Reserve for saw module FC 141

700156 0 0 Saw clamping vice inactive

700157 0 0 Saw clamping vice not closed

700158 0 0 Saw clamping vice not open

700239 0 0 Wrong supply to FB 126 password

Error messages must be acknowledged by pressing the

“Reset delete” key.



6. 18. Trouble shooting

6.18.1 No drill call-up

Cause Remedy

♦ Tool mode “OFF“ active. − Turn on „Automatic“ mode.

♦ Spindle only extends for a short time.

Tool „test“ mode active.

− Turn on „Automatic“ mode.

♦ Drill only makes a mark and immedi-

ately returns to its home position. Tool

mode „ Pop marking“ active.

− Turn on „Automatic“ mode.

♦ Message hydraulic fluid level too low. − Check fluid level and replenish

♦ Message clean hydraulic fluid filter. − Clean fluid filter



6.18.2 No Y,Z,W and Q-axis movement on the drill and no U

and Y movement on the Signomat and saw

Cause Remedy

♦ Home position of spindles 1,2 or 3 not

indicated.

− Check limit switch

♦ Message + Y software limit switch, plus

end limit Y-axis reached.

− JOG mode minus key of the appropriate

axis, release axis.

♦ Message -Y software end limit switch,

minus end limit of an axis reached.

Message – software limit switch of an

axis

− JOG mode plus key of the appropriate

axis, release axis

− Press RESET key

♦ Feed at 0 percent. − Increase feed

♦ „Feed hold“ on. − Press „Feed start“ key

6.18.3 No X-axis movement

Cause Remedy

♦ Home position of spindles 1, 2 or 3 not

indicated

− Check limit switch. All spindles must be in

the topmost position.

♦ Feed at 0 percent. − Increase feed.

♦ „Feed hold“ on. − Press „Feed start“ key.

♦ Clamp stations not closed − Close clamp stations



6.19 Summarised operating instructions

6.19.1 Turning the system on

1. Check compressed air and coolant reservoir

2. Set main switch to ON

3. Wait till the basic screen appears (enter the pass-

word in the case of a mains power board or press

INPUT key)

4. Press key Control ON and wait till the hydraulic

system has started up

5. Press the keys Secure system and Spindle start

in succession

6. Press key Stand-off* if necessary

7. Switch on the material handling system

8. The machine is now ready and is in JOG mode

* When the stand-off automatic mode is enabled,

the drills stop at a distance of approx. 20 mm

from the work-piece on the return movement

after the holes have been drilled.



6.19.2 Jog mode

X = work-piece axis

Y = web drill assembly axis

Z = flange drill assembly axis clamping side

W = flange drill assembly axis on the material

feed side with Signoscript

Q = Z tower

V = saw gearbox

U = slewing the saw*

1. Select the axis to be traversed

2. Press the key Secure system

3. Press key + or – (also press RAPID

for the raid feed key)

4.The axis can only be traversed with

the material clamped in position

* + Saw slews in clockwise direction –

saw slews in anti-clockwise direction



6.19.3 MDA mode

1. Press key MDA

2. Enter data if MDA memory empty

3. If the MDA memory is full, either press key MDA

buffer delete or select data using the blue arrow

keys and press key DEL and then enter new value

4. Press key Cycle Start

5. If M30 is not indicated in the MDA buffer as the last

line (programme end), the programme must be

interrupted by pressing the Reset key

6. To skip a block ( fade out ), a semi-colon can be

entered in front of the block

For example:

M22¶;M23¶M30¶”eof”

eof means “end of file” = end of programme



6.19.4 Loading programmes

The Control ON must have been pressed and no

programme should be in process

Keep the ALT key pressed, press the F key and then load

the programmes with the FD software

( refer to page „ single part output FD software )

and move to AUTO mode

1. Press key Menu select

2. Press softkey Programme

3. Press softkey Parts Programme

4. Use cursor to select MPF programme

5. Press key Select

6. Go back to basic screen by pressing key M Machine

Concerning points 4 and 5: when the parts programme has

been selected, you only need to press Menu Select twice

and you will be back in the parts programme



6.19.5 Deleting programmes

7. Press key Menu Select


9. Press key Parts Programme

10.Select programme to be deleted by pressing the

arrow key

6.19.4 Deleting a programme

1. Press key Manage Programmes

2. Press softkey Delete

3. Question: Delete the marked files with the softkey

No,

Reply: Yes all of them, Yes or Stop

Press the softkey << after deletion in order to select further

programmes

6.19.5 Deleting several programmes

1. Mark the programmes using the Select key

2. Back to point 1 (delete a programme)

Concerning points 2 and 3: when the parts programme has been selected, you

only need to press the Menu Select key twice and you are back in the parts

programme

!!X!! When this symbol appears on “Loaded”, then you have stored different

programmes with the same number in the control and on the hard disc.



6.19.6 Processing parts programmes

The Control ON key must have been pressed and

no programme in process

1. Change over to Auto mode



4. Press key Parts Programme

5. Use cursor to select MPF programme

6. Press softkey Select

7. Press key M Machine

8. Following keys must be pressed (green LEDs above

the keys must light up)

Auto, Tool, Automatic, Secure system, Spindle start and Feed

start and if required:

Drill hold-down1 ON, drill hold-down2 ON, Trim cut ON, hold-

down saw ON, coolant drills, stand-off automatic.

9. Press key Cycle Start

Follow instructions on screen Start = Secure system



6.19.7 Single part output ( FD software only )

1. Keep the ALT key depressed and then press the

letter F

2. Press key Single part output

3. Press key (S)elect

4. Select the part to be processed

4.1 Using the arrow key to the left you can move

from PART POSTION to DRAWING

4.2 Using the same arrow key, you can subsequently

move to JOB

4.3 At this point you can change the JOBS using

the arrow key up or down

4.4 Using the yellow Input key, you can jump back to

the DRAWINGS

4.5 Carry on to PART POSITION using the yellow Input

key

5. Press (C)ontinue twice

6. Enter stock length of section

7. Answer the prompt: web probes? (Y)es or (N)o

8. Part programme is written on the hard disc

9. Press key [ to move to basic menu

10. Press key ] to exit the FD software



6.19.8 Manual entry of a programme



3. Press either the Parts Programme softkey to

create an MPF programme or the Sub-programme

key to create an SPF programme

4. Press softkey New

5. Enter file name

6. Press softkey Ok

7. The edit window opens and data can be entered

8. When the programme has been entered, press soft

key Close Editor

Jump back to basic screen by pressing the M Machine

key




Tools


7.2 Basic data (guidelines) for drilling operations 7 – 2

7.3 Drill bits for dry drilling 7 – 3

7.4 Oil hole drill bits 7 – 3

7.5 General notes on drill bits 7 – 3

7.6 Grinding the bits 7 – 4

7.6.1 Cutting edge angles 7 – 4

7.6.2 The back chamfer a 7 – 4

7.6.3 The wedge angle ß 7 – 4

7.6.4 The cutting angle rake Y 7 – 5

7.7 Acute grinding and pointing 7 – 5

7.7.1 Pointing 7 – 5

7.7.2 Acute angle 118°, normal grinding 7 – 6

7.7.3 Acute angle 135° with cross-grinding 7 – 6

7.7.4 Point grinding „ K „ 7 – 7

7.7.5 Simplified point grinding 7 – 5

7.7.6 Acute angle 135° with point grinding 7 – 7

7.7.7 „K“ point grinding of oil hole drill bits 7 – 7

7.8 Points to be observed when grinding 7 – 6

7.9 Drill defects and their most frequent causes 7 – 8

7.10

7.11

7.12

7.13

Summary of defects

Saw blades LC 1250

7.11.1 Blade dimensions

7.11.2 Universal saw blades for steel construction

7.11.3 Saw blades for solids

7.11.4 Saw blades for thin walled sections

Blade data

7.12.1 Blade Z5, 1250 mm dia.

7.12.2 Blade Z3, 1250 mm dia.

7.12.3 Blade Z8, 1250 mm dia.

Blade rates of feed

7 – 9

7-10

7-10

7-10

7-10

7-10

7-11

7-11

7-12

7-13

7-14

Rates of feed 7-14



7 DRILL BITS

7.1 Introduction

This chapter will enable you to gather important information on drilling operations, drill

bits, drill faults as well as on the drilling capacity of your BDL 1000/9 Drilling Machine.

The Peddimat BDL 1000/9 is equipped with a system for the use of internally cooled drills

( oil hole drills ) for achieving exceptionally high output. You can, however, also use nor-

mal commercial HSS drill bits. Pay attention in this connection to the basic data specified

in this chapter on drilling operations.

7.2 Basic data ( guidelines ) on drilling operations

D [mm] s [mm/rpm]n [rpm]

s [mm/min]

8 0,19 510 108

9 0,20 510 115

10 0,21 510 121

11 0,22 510 127

12 0,23 510 133

13 0,24 510 138

14 0,25 510 142

15 0,26 510 138

16 0,27 497 133

17 0,28 468 129

18 0,28 442 126

19 0,29 419 122

20 0,30 398 119

21 0,31 379 116

22 0,31 362 114

23 0,32 346 111

24 0,33 332 109

25 0,34 318 107

26 0,34 306 105

27 0,35 295 103

28 0,35 284 101

29 0,36 274 99

30 0,37 265 97

31 0,37 257 96

32 0,38 249 94

34 0,39 234 91

36 0,40 221 89

38 0,41 209 86

40 0,42 199 84



7.3 Drill bits for dry drilling

Use normal commercial HSS drill bits for dry drilling.

7.4 Oil hole drill bits

So-called oil hole drill bits (internal coolant drills) are used, in particular, to achieve high

output.

The coolant emulsion is forced through the cooling ducts at a pressure of 5 to 8 bars.

This ensures that the drill is cooled and, at the same time, the coolant exiting under

pressure serves to improve the discharge of swarf and chips.

Oil hole drills guarantee long service life. Such tools have been used extensively on Ped-

dimat systems and have proven to be extremely economic.

7.5 General notes on drill bits

The general notes on drilling tools apply both to HSS and oil hole drill bits.



7.6 Grinding the bits

The wedge is the basic form common to all cutting tools for chip removing processes. The

more acute the wedge angle , the sharper the cutting edge. The blunter the wedge angle,

the greater the stability of the cutting edge. A compromise must be found between

these two extremes suitable for the material to be processed.

7.6.1 Cutting edge angles

7.6.2 The back chamfer

The back chamfer cutting angle keeps the friction between the clearance face and the

cutting face of the work-piece as small as possible. If the back chamfer angle is too

small, both the heat generated and the force of the drill will increase. In addition, the bit

will be more susceptible to breakage. If the back chamfer angle is too big, the wedge

cutting edge will become too weak with the result that it blunts quickly or breaks off.

In practice, back chamfers of between 5 and 14° are used. The back chamfer angle se-

lected in each individual case depends on the bit diameter, the material to be drilled and

the rate of feed.

7.6.3 The wedge angle ß

The wedge angle should be selected such that the wedge body is strong enough to with-

stand the cutting pressure.

The angle of rake determines the direction in which the chip is discharged after being

removed from the work-piece The larger the angle of rake, the easier the chip dis-

charges. The rake angle selected must not, however, be too big as this may result in the

cutting edge not being able to withstand the pressure exerted on it by the drilling opera-

tion..



7.7 Acute grinding and pointing

7.7.1 Pointing

The cutting angle rake adjacent to the chisel edge of a twist drill is negative. The chips

removed by the chisel edge discharge only very slowly. Pointing of the drill bit mainly

serves to enhance the rake, chip discharge at the chisel edge and bring about a reduction

in the width of the chisel edge.

7.7.2 Acute angle 118 °, normal grinding

The 118° tip angle is generally applied to multi-purpose drill bits and normally used for

drilling construction steels and for holes that are not too deep.

7.7.3 Acute angle 135° with cross-grinding

The 135° angle with cross-grinding is used for deep-hole drill bits and bits with reinforced

core. The 135° tip angle increases the stability of the cutting edges. The cross-grinding

considerably reduces the required rate of feed. This is of particular advantage on difficult-

to-machine materials. Good centering and cutting properties facilitate drilling and guar-

antee maximum accuracy holes. In addition, the chip breaking qualities are enhanced.



7.7.4 Point grinding "K"

Point grinding „K“ is primarily used on HD drill bits ( bits with reinforced core ). The acute

angle can be 118 or 135°.

We recommend point grinding „K“ for drilling operations on tough materials and for all

materials that are difficult to cut.

Point grinding „K“ provides the main cutting edge with a positive rake of 4 to 8°, and

with a reduction in the width of the cross cutting edge. This improves centering of the

drill bit and also reduces the feed pressure required. Pointing „K“ also lends the drill bits

good chip breaking qualities.

7.7.5 Simplified point grinding

This type of point grinding is suitable for all types of drill bit. The bit is provided with en-

hanced centering qualities and the feed pressure is also reduced. This form of grinding

can also be performed manually by operators not so skilled in the sharpening of tools.

The width of the chisel edge should be reduced to 10% of the bit diameter.



7.7.6 Acute angle 135° with point grinding

The acute angle of 135° with point grinding is recommended for heavy-duty drilling op-

erations on difficult-to-cut materials such as, for example, manganese steel, austenitic

steels and high temperature steels up to hardness of 52 HRC.

The pointing of the drill bit means that the cutting edges are provided with a rake of 3 to

8° and a reduced chisel edge width. Pointing is effected up to half of the main cutting

edge. The chisel edge width is reduced to between 2% and 9% of the drill diameter.

7.7.7 „K“ point grinding of oil hole drills

Point grinding here corresponds to that described in Chapter 5.3.3.4 but modified to ca-

ter for oil hole drills. The four cutting edges formed by the „K“ point grinding lend the

drill bit good chip breaking qualities.

7.8 Points to be observed when grinding

♦ The main cutting edges must be of identical length and height.

♦ The point grinding must be performed centrally and uniformly on both cutting faces.

♦ Always take care to ensure a smooth flow of chips.

♦ The acute angle must have the correct back chamfer.

♦ Damaged or worn lands must be removed by shortening them prior to commencing

grinding operations.

♦ Avoid burning or drawing of the drill temper.

♦ If possible, the drills should be reground and pointed using an appropriate machine.

♦ Bent drills must be straightened before regrinding.



7.9 Drill defects and the most frequent causes

In this example, excessive cutting speed was

the cause. The outer corners of the bit have

worn too quickly as a result of the cutting

speed being too high and the temper having

been drawn.

The back chamfer on the cutting lip of the

drill here was inadequate. As a result, the

drill no longer had a cutting edge and was

split right down the middle by the feed pres-

sure.

Here you can see the results of the back

chamfer on the cutting lip being to big. The

cutting edges have chipped due to insuffi-

cient support.



7.10 Summary of defects

Fault Cause

♦ Outer corners break off • Excessive cutting speed.

• Hard spots in the material.

• Cutting oil doesn’t reach the tip of the

drill.

• Drill flutes clogged with chips.

♦ Cutting edges chip • Feed rate too high.

• Back chamfer on the cutting lip too big.

♦ Cracks in the cutting edges • Drill point incorrectly ground.

• Rate of feed too high.

• Drill blunt.


♦ Drill bit breaks • Drill point incorrectly ground.

• Feed rate too high.

• Drill blunt.


♦ Drill taper breaks • Poor fit between taper and chuck caused

by dirt or chips.

• Burr in the chuck or chuck severely

worn.

♦ Drill bit splits through the centre • Back chamfer too small.

• Rate of feed too high.

♦ Drill doesn’t bite • Drill blunt.

• Back chamfer too small.

• Core too strong.

♦ Hole has rough surfaces • Drill point incorrectly ground or blunt.

♦ Hole too big • Cutting edge angles not identical or cut-

ting edge length not identical or both.

♦ The shape of the chips changes during

drilling operations

• Drill becomes blunt or cutting edges

have chipped.

♦ Large chip from one flute, small chip

from the other flute

• Drill point incorrectly ground,

• One cutting edge is doing all the work.



7.11 Saw blades

7.11.1.1 Blade dimensions

( LC circular cold saw only )

The outside diameter of a new blade on the LC 1250 circular cold saw is

1250 mm.

The smallest outside diameter of a blade that has been reground

must not be less than 1220 mm.

7.11.1.2 Universal saw blades for steel construction

We recommend a blade with a tooth pitch of Z5 for general work. Using

this type of blade will enable you to cut most of the rolled sections and

qualities employed in steel construction with good cutting results. This

makes it possible to dispense with frequent changing of the blade.

7.11.1.3 Saw blades for solids

We recommend a blade wit Z3 tooth pitch for cutting solids and especially

for thick walled sections.

7.11.1.4 Saw blades for thin walled sections

We recommend blades with a tooth pitch of Z8 for cutting thin walled

sections.

The appropriate chip remover ( wheel ) must be used each time

the saw blade is changed. Refer to Chapter 9.



7.12 Saw blade specifications

7.12.1 Saw blade Z5, 1250 mm diameter

V = roughing tooth

N = cutting tooth

S = kerf

T = tooth pitch

γ = rake

∝ = back chamfer

t1 = tooth depth

r = tooth flow radius

h = height difference

a = width of roughing tooth

r ~ 0,25 x T

a = 0,33 x S –h

Outside diameter D 1250 mm

Kerf S 9 mm

Blade thickness S' 7 mm

No. of segments 36

No. of teeth per segment 5

Arbour diameter d1 100

H7

mm

No. of pitch circle holes 4 per pitch circle

Pitch circle hole diameter d2 32 mm

Pitch circle diameter d3 220 mm

+0,2

Rake 18°

+2°

Back chamfer 8°

+2°

Max. axial run-out 0,1 mm

Max. side run-out 0.2 mm clamping flange Diameter 300 mm

Height difference h 0,6 mm – 0,7mm

Coolant flutes

Ja, Breite = 13 mmBlade weight 67 kg




V = roughing tooth

N = cutting tooth

S = kerf

T = tooth pitch

γ = rake

∝ = back chamfer

t1 = tooth depth



a = width of rough tooth

r ~ 0,25 x T

a = 0,33 x S –h


Kerf S 9 mm


No. of segments 36



H7

mm




+0,2

Rake 18°

+2°

Back chamfer 8°

+2°


Max. side run-out 0.2 mm clamping flange diameter 300 mm

Height difference h 0,6 mm – 0,7mm

Coolant flutes yes, width = 25 mm

Blade weight ~67 kg




V = roughing tooth

N = cutting tooth

S = kerf

T = tooth pitch

γ = rake

∝ = back chamfer

t1 = tooth depth



a = width of roughing tooth

r ~ 0,25 x r ~ 0,25 x T

a = 0,33 x S –h


Kerf S 9 mm


No. of segments 36



H7

mm




+0,2

Rake 18°

+2°

Back chamfer 8°

+2°


Max. side run-out 0.2 mm clamping flange diameter 300 mm

Height difference h 0,4mm – 0,5 mm

Coolant flutes no

Balde weight ~67 kg



7.13 Blade rates of feed

Circular cold saws operate automatically and program controlled. The blade rates of

feed are specified by the programme depending upon the dimensions of the work-

piece to be cut.

The smallest outside diameter of a blade that has been reground must

not be less than 1220 mm.

Make sure that a newly fitted blade is moistened with coolant before

performing the first two to three cuts. Start to cut with reduced feed

rate ( approx. 60% of max. rate).Warning!




The Signoscript (OPTION)

8.1 Description 8 – 2

8.2 Notes on safety 8 – 3

8.3 Start-up 8 – 4

8.3.1 Adjusting the rate of advance and pressure 8 – 4

8.3.2 Adjusting the marking depth 8 – 5

8.4 Maintenance 8 – 6

8.5 Changing the tools 8 – 7



8 THE SIGNOSCRIPT

8.1 Description

The positioning axis of the W drill assembly represents the vertical feed axis for the

Signoscript, the X-axis is the horizontal feed axis.

The mill cutter is advanced to the work-piece by compressed air cylinder.

The pressure and the speed of the compressed air cylinder are infinitely variable.

The marking depth of the mill cutter can be set accordingly by inserting or removing wa-

fer thin metal plates from under the spacer block –1- . The maximum marking depth of

1.5 mm should not be exceeded.

1



8.2 Notes on safety

Please pay specific attention to the notes on safety when operating and working on the

marking system.

♦ Always turn the main disconnect switch off before carrying out any repair,

servicing or maintenance work.

♦ If the system is hooked up to factory supply lines, the system is only to be

put into operation when the point of sourcing is made safe and the prescribed

safety equipment is in place.

♦ The operator must make sure that the system is ready for operation prior to

beginning work ( change of shifts ).

♦ The operator should be equipped with safety gloves, safety shoes, leather

apron and safety glasses. Ear protectors are also recommended.

♦ No mechanical modifications or additions are to be made to the system.

Warning!



8.3 Start-up

8.3.1 Adjusting the rate of advance and the pressure

The supply of compressed air is effected for the Signoscript by an oiler –1- and

a pressure reducing valve -2-. One-way restriction valves are located on the compressed

air cylinder for advancing the Signoscript for incoming and outgoing air.

The pressure reducing valve regulates the pressure applied to the mill cutter. The one-

way restriction valves -3- serve to adjust the rate of advance. This should be set such

that the mill cutter does not impact the work-piece too hard.

1

2

3



8.3.2 Adjusting the marking depth

The marking depth of the mill cutter can be set by inserting or removing wafer thin metal

plates from under the spacer block –1- . The maximum marking depth of 1.5 mm must

not be exceeded.

1



8.4 Maintenance

The supply of compressed air for the Signoscript is effected by an oiler –1- and a pres-

sure reducing valve –2-.

The oil level of the oiler must be checked daily.

Replenish, if necessary.

Only fill with resin and acid-free HL 32 oil!

1

2

Warning!



8.5 Changing the tools

Observe all safety instructions!

Action: − traverse the W drill assembly to a centre position.

− press key 3 „ Enter danger zone „ on the control console


• the LED display above the key lights up



− remove the spacer block by loosening the four fastening

screws.

− release the mill cutter with the aid of the special wrench by

turning it in anticlockwise direction and pull it out of the

mounting..

− lock the mill spindles with a hexagon socket wrench on the

clamping screw to prevent it from turning.

fit the new mill cutter in reverse sequence.

− close the safety gate

− press key 4 „ Secure system „ on the control console


− the LED display above the key lights up.

♦ Only use original tools!

Warning!

Warning!




Servicing and Maintenance


9.2 Maintenance and inspection list 9 – 2

9.3 Instructions on how to act 9 – 4

9.4.1 Work on the machine 9 – 4

9.4 Servicing the feed gearbox 9 – 4

9.5 The drill assembly 9 – 5

9.5.1 Servicing the drill assembly gearbox 9 – 5

9.5.2 Changing oil Y-axis 9 – 6

9.5.3 Changing oil Z and W-axis 9 – 7

9.6 The lubrication schedule 9 – 8

9.7 The hydraulics 9 – 9

9.7.1 Care and maintenance of the hydraulics 9 – 9

9.7.2 Recommended oils 9 – 9

9.7.3 Checking the oil level 9 – 10

9.7.4 Replenishing oil 9 – 11

9.7.5 Changing the oil 9 – 12

9.7.6 Cleaning the return filter, changing the filter ele-

ment

9 – 13

9.8 Care and maintenance of the electrical system 9 – 14

9.9 The CNC control 9 – 14

9.10 The main power section 9 – 14

9.11 The axis drives 9 – 14

9.12 System wiring and electrical components 9 – 15

9.13 Cooling the drill bits 9 – 15

9.14 Cooling lubricant 9 – 15

9.14.1 Checking the coolant system 9 – 15

9.14.2 Disposal 9 – 15

9.14.3 Fault/damage notification 9 – 16



9 SERVICING AND MAINTENANCE

9.1 Introduction

The steps and instructions contained in this chapter presuppose, depending upon the

field of activity, a longer period of technical and/ or electro-technical training. Generally

valid safety regulations, in-depth technical knowledge and knowledge of how to act prop-

erly are also presupposed and are not set out separately(refer to sections 1.3 / 2.4 /

2.10 / 2.11). The working hours (h) or intervals contained in the maintenance and in-

spection list are based on single-shift operation. Maintenance and servicing work must be

carried out earlier in the case of multi-shift operation.

The Peddimat BDL 1000/9 flat bar drilling and flame cutting machine must be regu-

larly checked, serviced and maintained. Please observe all pertinent instructions and

regulations.

Should any questions arise that have not been dealt with in this manual, please call the

Peddinghaus service department. You will always reach a competent contact on phone

No. 02332 / 72-0.

You can also contact the service department by fax on 02332 / 72 - 280.

Use the attached damage notification form to notify the manufacturer

of malfunctions and faults that occur enabling them to take the neces-

sary steps to your satisfaction.

9.2 Maintenance and inspection list

B = operator WP = maintenance person-

nel

SP = manufacturer’s service personnel

Operating hours

(h) or interval

Check point maintenance instructions Work aids Pers.

8 / daily

Chap 9.7.3 / 9.7.4 >

Chap. 6.15 / 6.16 >

Chap. 7.7 >

− Check the pneumatic pressure on the cool-

ing system (max. 8 bars)

− Check system for cleanliness, clean if neces-

sary.

− Check oil level of hydraulics, replenish in

necessary

− Check coolant level

− Check the drill bits, regrind or replace if

necessary

Spray oil

B

40 / weekly

Chap. 9.5.1 >

Chap. 9.6 >

Chap. 9.11 >

Chap. 9.12 >

− Check oil level in drill assembly gearbox,

replenish if necessary

− Lubricate system components

− Clean axis drive filters

− Check/clean end limit switches

BP GR-XP

150

Roller bear-

ing grease.

B

WP

WP

200 / once after

start-up

Chap. 9.5.2 > − Change oil in drill assembly gearbox

BP GR-XP

150

WP



Operating hours

(h) or intervals

Check point maintenance instructions Work aids Pers.

160 / monthly

Chapter. 9.6 > − Lubricate system components Roller bear-

ing grease

B

480 / 3 months

Chap. 9.7.5 >

Chap. 9.7.6 >

Chap. 9.12 >

− Change oil on hydraulics (once after start-

up)

− Clean return filter / replace filter element

− Check electrical connecting cables for dam-

age

refer to

chap. 9.7.2

filter ele-

ment

WP

1000 / 6 months

Chap. 9.9 >

Chap. 9.7.5 >

Chap. 9.7.6 >

Chap. 9.10 >

Chap. 9.12 >

− Check all electrical cabinets for contamina-

tion or dirt

− check electrical connections in the switch

cabinets and on the whole system for tight-

ness

− Check all safety equipment. The following

parts must be checked individually:

− fence and safety gates for:

− condition

− tightness

− safety switch function

− light barrier components for:

− condition

− tightness

− functionality

− all E-stops for:

− condition

− functionality

− safety limit switches / signal lamps for:

− condition

− fastening

− functionality

− check CNC control for proper function

− change oil on hydraulics

− clean return filter / replace filter element

− carry out maintenance work on main power

section

− check encoder connections and couplings

refer to

chap. 9.7.2

filter ele-

ment

WP

2000/ 12 months

Chap. 9.5.1 >

Chap. 9.11 >

− change oil in drill assembly gearbox

− check axis drives

− check overall system functionality

Mobil Gear

629

WP

SP

4 - 6 years − replace hoses

• hoses must be replaced every 6 years

from date of manufacture erneuert werden

WP



9.3 Instructions on how to act

♦ All safety equipment and parts that are dismantled must be properly

replaced prior to renewed start-up and checked for correct function.

Even when this is not mentioned in individual cases.

♦ If re-assembly is performed in reverse sequence to dismantling, it

will still not be described separately but summarised under the term

„ assembly“.

9.3.1 Work on the machine

The following points must be observed prior to performing maintenance work:

− turn off main switch and secure against unauthorised or unintentional re-starting

− depressurise the hydraulics and pneumatics

− secure machine against unauthorised use by means of warning signs

• slipping and stumbling when working on the machine

− danger of injury to parts of the body

Only work on the machine with the aid of suitable platforms and make

sure they are adequately stable!

Only use original parts when replacing components on the hydraulic system, check with

manufacturer, if necessary.

The following points are to be observed subsequent to work on the hydraulics:

− check oil level; replenish, if necessary

− carry out functionality check (refer to chapter 6.7)

9.4 Maintenance of the feed gearbox

Under normal operating conditions, the feed gearbox is maintenance-free.

Warning!



9.5 The drill assembly gearbox

9.5.1 Servicing the drill assembly gearbox

The drill assembly

Action:

gearbox has a charge of oil.

Check oil level on the observation glass once a week

Replenish with oil when no oil is visible on the observation glass in

the following manner:

− traverse drill assembly to suitable position

− turn off the main disconnect switch

− open the vent plugs - 2 -

− replenish with gearbox oil (BP GR-XP 150)

− check oil level and close the vent plugs

−

• slipping and stumbling


Immediately absorb oil that has overflowed or spilt and remove!

Observe the current regulations ( accident prevention act ) when disposing of oil

and cleaning agents.

1

2

Caution!



9.5.2 Oil change – drill assembly gearbox Y

It is imperative to make the first gearbox oil change after 200 working hours.

Afterwards, change the oil once a year.

Action: − traverse the drill assembly to the right or left-hand position


− remove the oil drain plug – 1 -

− screw off the vent filter - 2 -

− collect the old oil in a suitable vessel (cap. approx.15 litres )

− screw in the oil drain plug

− screw on the hold-down cylinder

− pour in approx. 12 litres of gearbox oil (BP GR-XP 150) and

check oil level on observation glass

− screw on the vent filter - 2 –



Immediately absorb oil that overflowed or spilt and remove!



Caution!



9.5.3 Oil change – drill assembly gearbox Z and W

It is imperative to make the first gearbox oil change after 200 working hours.

Afterwards, change the oil once a year.

Action: − traverse the drill assembly to the right or left-hand position


− remove the oil drain plug – 1 -

− screw off the vent filter - 2 -

− collect the old oil in a suitable vessel (cap. approx.15 litres )

− screw in the oil drain plug

− screw on the hold-down cylinder

− pour in approx. 12 litres of gearbox oil (BP GR-XP 150) and

check oil level on observation glass

− screw on the vent filter - 2 –



Immediately absorb oil that overflowed or spilt and remove!



Caution!



9.6 The lubrication schedule

The machine must be greased regularly. All lubrication points are to be greased prior to

initial start-up.

Symbol Lubricant Greasing intervals

Roller bearing greaseOnce a month with grease gun

Gearbox oil BP GR-XP

150

Initial oil change after 200 working hours, then

once a year after that.



9.7 The hydraulics

9.7.1 Care and maintenance of the hydraulics

The minimum starting temperature of the hydraulic oil is between 12 and 14°C. The

standard operating temperature is approx. 50°C. When temperatures are low and in win-

ter, the system must be allowed to warm up for 15 – 30 minutes before commencing

operation of the machine. This will guarantee proper functioning.

The pressure settings on the hydraulic power-pack and on the hydraulic pump

are only to be made by Peddinghaus service personnel or by authorised engi-

neers. Warranty will immediately expire if third parties are allowed to perform

such work.

9.7.2 Recommended oils

The power-pack has a capacity of 160 litres. The initial charge of oil is included in the

scope of supply.

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

tem depend on careful selection of the hydraulic oils.

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

phenomenon, avoid disturbing deposition and cavitation, and prevent undesirable reac-

tions of penetrated water, in addition to additives providing for improved anti-corrosion

protection and ageing resistance plus reduced wear.

The hydraulic oils listed below have suitable for numerous Peddinghaus sys-

tems. Please, therefore, only use these oils or products as far as possible which

are in accordance with DIN 51 524 dated June 1985.

Types of oil

Manufacturer

30° C (VG 46) 0....30° C (VG 32)

ARAL VITAM DE 46 VITAM DE 32

BP ENERGOL HLP - D 46 ENERGOL HLP - D 32

ESSO H - LPD oil 46 H - LPD oil 32

HS RENOLIN MR 15 RENOLIN MR 10

MOBIL Hydraulic oil H - LPD 46 Hydraulic oil H - LPD 32

MOBIL MOBIL D.T.E 25 MOBIL D.T.E 24

SHELL HYDROL DO 46 HYDROL DO 32

WINTERSHALL WIOLAN HG 46 WIOLAN HG 32



9.7.3 Checking the oil level

The oil level is to be checked each time before starting production.

Action: − Check oil level on observation glass -5-. Pour in oil up to 1 cm

below the maximum mark.

Should the oil level drop below the minimum mark during machine operation,

then the tank must be replenished immediately.

5



9.7.4 Replenishing the oil

When the oil has dropped below the minimum mark, hydraulic oil must be replenished

( observe the recommended oils ).

The tank heater connecting terminals are still live even when the main switch

has been turn off. The main disconnect switch DO-Q 22 in the power section of

the electrical switch cabinet must be turned off when carrying out repair work or

changing the oil.

Action: − Turn of the main switch

• the hydraulic system is now depressurised.

• the pressure gauges must be at zero

− Open the tank filler cap -2- and pour in fresh hydraulic oil

− Close the filler cap.

• Slipping and stumbling

− Danger of injury to parts of the body

Immediately absorb oil that has overflowed or spilt and remove!

Observe the current regulations ( accident prevention act ) when disposing of

oils and cleaning agents.

2

Caution!

Danger!



9.7.5 Changing the oil

♦ Initial oil change after 500 working hours ( refer to hour meter in the switch

cabinet ). Further oil changes after 1.000 working hours, at the latest, how-

ever, after 12 months. The line return filter is to be cleaned and the filter

element replaced each time the hydraulic oil is changed.

The tank heater connecting terminals are live even when the main disconnect

switch has been turned off.

The main disconnect switch DO-Q 22 in the power section of the switch

cabinet must be turned off when carrying out repair work and when

changing the oil!

Action: − Turn off the main switch

• The hydraulics are now depressurised.

• The pressure gauges must be at zero

− Open tank filler cap - 2 - , remove filter insert

− Draw off the old oil using a barrel pump

− Screw off the cap (manhole ) - 1 – and clean the tank

− Remount the cap

- Pour in approx. 160 l fresh oil (observe oil recommendations )

− Check oil level on observation glass -5- . Fill with oil up to 1cm

below the maximum mark

− Close tank cap

− Check oil level on observation glass again at operating tem-

perature

Observe current regulations ( accident prevention act ) when disposing of oil and

cleaning agents.

2

1

Danger!



9.7.6 Cleaning the return filter, changing the filter element

Pre-conditions: ♦ The system must be completely turned off.

♦ The main switches for the overall system must mist be at posi-

tion 0.

♦ The filter must be relieved on the pressure side.

Action: − Lift up the filter cap -2- after releasing the four hexagon screws

to remove and pull out the filter element

− Pull the filter bell together with the element up and pull out

− Remove the filter element-4- by gently moving it back and

forth.

− Clean the filter cap -2- and the filter bell -5- with benzine or

petroleum

− Take the new filter element out of the plastic cover and fit in

reverse sequence

Check the O-rings on the filler cap -2- and on the filter bell -5- for damage and

replace, if necessary. Also check whether the part No. on the insert element

coincides with the number on the nameplate.



9.8 Care and maintenance of the electrical system

Checks and maintenance work on the electrical system and electronic apparatus are only

to be carried out by authorised, qualified personnel.

We recommend that you take out a maintenance contract: this will give you the

comforting thought that your machine, especially the electrical and electronic

equipment, is receiving qualified attention in respect of maintenance.

Action: − check all electrical switch cabinets for contamination or dirt

− clean the air filters in the cabinets / replace

− check all electrical connections in the switch cabinets and on

the complete system for tightness

♦ Check all safety equipment. The following parts must be

checked individually:

− fence and safety gates for:

− condition

− tight seating

− safety switch function

− light barrier components for:

− condition

− tight seating

− functionality

− all E-stops for:

− condition

− functionality

− safety limit switches / signal lamps for:

− condition

− fastening

− functionality

9.9 The CNC control

Check the function of the controls every 6 months.

9.10 The main power section

Action: − Clean switchgear and components every 6 months.

− Check terminal connections once a year.

− Check control and auxiliary voltages every 12 months and ad-

just, if necessary.

9.11 The axis drives

Action: − Clean the filters weekly.

− Check terminal connections every 12 months.

− Carry out adjustments every 12 months.



9.12 System electrical components and wiring

Action: − Clean limit switches once a week.

− Check cables every 3 months for mechanical damage; espe-

cially in the vicinity of the drill spindles ( swarf ).

− Check terminal connections every 12 months.

− Check encoder fixture and coupling every 6 months.

9.13 Cooing the drill bits

The BDL 1000/9 is equipped with an air coolant system for cooling the drills. A spray oil

is added to the air with the aid of micro dosing pumps.

9.14 Cooling lubricant

We recommend bio spray oil HP 42.

Do not fail to observe the contents of Chapter 9.15.4 „ Technical information

on coolant „ + Chapter 9.15.5 „ General requirements in respect of cooling

agents (KSS) „!

9.14.1 Checking the coolant system

Regularly check the coolant system for visual leaks, damage and sharp bends. Replace

damaged hoses.

• Spray oil

− Caustic burning of the hands and eyes

Do not fail to observe the instructions in chapter 2.4 of the instructions

manual pertaining to HP Microspray II part II when handling the spray

oil!

9.15 Disposal

Disposal is only to be effected by a company able to prove its competency and experi-

ence in this field.

Warning!



9.16 Fault/damage notification

Machine description:

Model :

Serial No. :

Year built :

The following q faults q damage have been incurred:

____

____

____

The following q faults q damage have been incurred on the control:

____

____

____

When was the fault/damage detected? Date: ____

In which mode was the fault/damage detected: ____

Was someone injured? q yes q no Was property damaged? q yes q no

Have steps already been taken or repair of the machine started? q yes q no

if so, which/what?: ____

Where and when can the machine be inspected? Date: ____

Name and address of the user:

Company : Contact: ____

Street: ____

Postal code/Town:

____

Telephone: Facsimile:

____

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

Complete the questionnaire carefully and send to:

Company: Messrs. Paul Ferd. Peddinghaus GmbH


Tel. + 49 (0) 2332 – 72– 0

Fax. + 49 (0) 2332 – 72 – 208




EC Conformity and Manufacturer’s Declarations

13.1 Manufacturer’s declaration of conformity Peddinghaus. 13 – 2



10 EC CONFORMITY AND

MANUFACTURER‘S DECLARATIONS

10.1 EC Declaration of conformity by the manufacturer

Operating Instructions

for

Saw- Drill Line

Typ

Peddimat- BDL 1000/9

Part 1

Operating Instructions

Manual

for

Saw/Drill Line

Model

Peddimat- BDL 1000 / 9

Part 2


Peddimat – BDL 1000/9 Part 2

Part 2

Operating Instructions for peripheral

components

Chap 1

System drawings Chap 2

2.1 Installation layout

2.2 Hydraulic circuit drawings

Electrical system - machine Chap 3

3.1 Bill of material

3.2 Circuit drawings

3.3 Descriptions

Company: Paul Ferd. Peddinghaus GmbH


Tel. + 49 (0) 2332 – 72 - 0

Fax. + 49 (0) 2332 – 72 - 208



Operating instructions for peripheral

components

Chap 1




2.1 Installation layout




2.2 Hydraulic circuit drawings




3.1 Bill of material




3.2 Circuit drawings




3.3 Descriptions


Peddimat BDL 1000/9 Chapter 13 / 1

13.1 EC Declaration of Conformity

as specified by the EC guidelines

Ξ Machines 98/37 EC, Annex II A

Ξ Electro-magnetic compatibility 89/336/EEC

Ξ Low voltage guidelines 73/23 EG

The machine

Make:

Model:

Drilling machine


is developed, designed and manufactured in accordance with the EC Guidelines 89/37 EC

under sole responsibility.

Firm: Paul Ferd. Peddinghaus GmbH, D-58285 Gevelsberg, Hasslinghauser Str. 156

The following harmonised standards are applied:

Ξ DIN EN 292-1/2 Machine Safety – Appliances and systems

Ξ DIN EN 294 Safe distances to prevent the upper limbs from reaching pinots of

danger.

Ξ DIN EN 349 Minimum safe distances to prevent crushing of parts of the body

Ξ DIN EN 418 E-stop facilities, functional aspects, design guidelines

Ξ DIN EN 953 General requirements in respect of design and assembly of separating

safety equipment.

Ξ DIN EN 954-1 Safety related parts of controls; general design guidelines

Ξ DIN EN 982 Safety requirements in respect of fluid operated systems and hydrau-

lic components

Ξ DIN EN 983 Safety requirements in respect of fluid operated systems and pneu-

matic components

Ξ DIN EN 1037 Machine Safety – prevention of unintentional start-up

Ξ DIN EN 1050 Machine Safety – risk assessment

Ξ DIN EN 1088 Locking devices with and with follower

Ξ DIN EN 50100-1 Non-contact safety appliances

Ξ DIN EN 50100-2 Non-contact safety appliances with active optical–electrical principle

Ξ pr EN 50081-2 EMC Standard Interference Transmission Industrial Field

Ξ pr EN 50082-2 EMC Standard Interference Resistance Industrial Field

Ξ DIN EN 60204-1 Electrical equipment of machines; general requirements

Ξ prEN 31202 Acoustics, noise radiation by machines

Complete technical documentation is available.

Ξ The appropriate operating instructions manual for the machine is available in

the original version.

ϒ The appropriate operating instructions manual for the machine is available in

the language of the country in which it is in use.

______________________ ______________________ _______________________

Place, Date Signature Details of person signing

Warning!

Caution!

Danger!

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