FDB1500-2500 Instruction Manual

INSTRUCTION MANUAL for FDB1500 & FDB2500 Plate Processing Systems
Operation/ Safety/ System Specifications/ Lubrication/ Mechanical Maintenance/ Hydraulics/

Pneumatics
CHAPTER 1 Introduction
Options Covered In This Manual:
Drill Spindle
Signoscript Part Marker
Plasma Torch
Oxy-Fuel Torch
May 26, 2006, Peddinghaus Corporation YD2313149, Rev 0
1Page
Table of Contents
Introduction Chapter 1
Title page
Chapter 1
Page 1
Table of Contents
Chapter 1
Page 2-5
This Manual
Chapter 1
Page 6
Peddinghaus Corporation
Chapter 1
Page 7
Machine Identification Page
Chapter 1
Page 8
Documentation
Chapter 1
Page 9
Conventions for Notes, Warnings and

Chapter 1
Cautions
Page 10
Safety Instructions
Chapter 1
Page 11
General Notes on Safety
Chapter 1
Page 12
Normal Operation
Chapter 1
Page 13
Maintenance / Adjustment
Chapter 1
Page 13
Special Sources of Danger
Chapter 1
Page 14
Lockout/ Tagout
Chapter 1
Page 14
Introduction
Chapter 2
Page 15
Optional features
Chapter 2
Page 15
Machine specifications
Chapter 2
Page 16-17
Major components
Chapter 2
Page 18
Major electric motors
Chapter 2
Page 19
Hydraulic Power Unit
Chapter 2
Page 20
Accumulators
Chapter 2
Page 20
Hydraulic cylinders
Chapter 2
Page 21-22
Chapter 2
Page 22-23
Electrical Cabinet
Chapter 2
Page 23-26
Misc. Electrical Equipment
Chapter 2
Page 27-28
Location of Emergency Stop (EStop) Buttons
Chapter 2
Page 29
Main Disconnect
Chapter 2
Page 29
Notes on Safety for Specific

Operational Modes
Machine Description Chapter 2
Hydraulic Equipment
Pneumatic Equipment
Pneumatics
Electrical Equipment
2Page
Maintenance Chapter 3
Introduction
Chapter 3
Page 30
Maintenance Safety
Chapter 3
Page 30
Lubrication Schedule
Chapter 3
Page 31
List of Recommended Lubricants
Chapter 3
Page 31
Metric Fastener Torques
Chapter 3
Page 32-33
SAE Hoses
Chapter 3
Page 34
ASA Steel Tube
Chapter 3
Page 34
Steel Pipe
Chapter 3
Page 35
Description
Chapter 3
Page 36
Pressure Adjustments
Chapter 3
Page 36
Temperature
Chapter 3
Page 36
Recommended Oil
Chapter 3
Page 37
Recommended Hydraulic Fluid

Specifications
Chapter 3
Page 37
Hydraulic Oil Level
Chapter 3
Page 38
Adding Hydraulic Oil
Chapter 3
Page 38
About oil and filters
Chapter 3
Page 39
Hydraulic Power Unit Shutdown

Procedure
Chapter 3
Page 39
Changing the Hydraulic Oil
Chapter 3
Page 40
Changing Hydraulic Power Unit

Filters
Chapter 3
Page 41
About Grease Fittings
Chapter 3
Page 42
Part exit side right
Chapter 3
Page 42-44
Part exit side center
Chapter 3
Page 44-46
Part exit side left
Chapter 3
Page 46
Part entry side
Chapter 3
Page 47
Drill Transmission
Chapter 3
Page 48
Specifications for Standard

replacement parts
Hydraulic power unit
Changing the Hydraulic Power Unit

Oil and/or Filters
Grease Fittings
3Page
Drill Coolant
Coolant Emulsion
Chapter 3
Page 49
Replenishing Coolant Emulsion
Chapter 3
Page 50
Pneumatic System
Lubricators
Chapter 3
Page 51
Mist Lubricator Filling
Chapter 3
Page 51
Oil delivery drip rate chart
Chapter 3
Page 52
Filter Draining & Replacement
Chapter 3
Page 53
Electrical System
Chapter 3
Page 54
Introduction
Chapter 4
Page 55
Daily Startup
Chapter 4
Page 55
Shutdown Sequence
Chapter 4
Page 56
Horizontal clamp
Chapter 4
Page 56
Smoke collector air flow adjustment
Chapter 4
Page 57
Drilling and drill bits

Drill-Bit Usage
Chapter 4
Page 58
Defects on Drill-Bits and Their Most

Chapter 4
Frequent Causes
Page 59
Drill Coolant System
Chapter 4
Page 60
About the Signoscript maker
Chapter 4
Page 61
Marker service
Chapter 4
Page 61-62
Marker Adjustment
Chapter 4
Page 63
About the Plasma-Torch
Chapter 4
Page 64
Torch tip adjustment
Chapter 4
Page 64
Torch Path Routing
Chapter 4
Page 65
Correct Torch-Travel Direction for

Various Cut-Offs
Chapter 4
Page 65-67
Kerf & Cutter Compensation

Definitions & Data
Chapter 4
Page 67-68
Optional Kerf Changes
Chapter 4
Page 68-69
Plasma torch Summary Notes
Chapter 4
Page 69
Operation Chapter 4
Signoscript marker Operation (if

feature present)
Plasma-Torch operation (if feature

present)
4Page
Oxy-Torch Operation (if feature

present)
Oxy-Fuel - General Safety
Information
Chapter 4
Page 70
The Work Area
Chapter 4
Page 70
Protective Apparel
Chapter 4
Page 70
Fire Protection
Chapter 4
Page 71
Vision Safety
Chapter 4
Page 71
Gas Control Panel
Chapter 4
Page 72-76
Pre-Operation
Chapter 4
Page 77
Oxy-Torch Operation
Chapter 4
Page 77
Cutting Chart Data Introduction

(Mild Steel)
Chapter 4
Page 78
Acetylene (one piece tips)
Chapter 4
Page 79
Natural Gas and Propane (one piece

tips)
Chapter 4
Page 80
Liquid. Air, MAPP gas, and

Propylene (one piece tips)
Chapter 4
Page 81
Liquid Air and MAPP gas (two piece

Chapter 4
tips)
Page 82
Natural Gas, Propane, Chem-o-lene,

Butane, and Flamex Model GPN
(two piece tips)
Chapter 4
Page 83
Propylene, Apachi, B-plus, H.P.G.,

RD, T-9, Ucon96, FG-2: Model GPP Chapter 4
(two piece tips)
Page 84
Kerf Definition and Size Range
Chapter 4
Page 85
Cutting and Piercing Information
Chapter 4
Page 85-86
Torch Tip Cleaning and Changing

Procedure
Chapter 4
Page 87-88
Painting / Colors
Chapter 4
Page 89
Chapter 6
Page 90
Oxy-Torch Operating Guidelines
Oxy-Torch Cutting Charts
Drawings & Bills Chapter 6

Assembly Drawings and Bills
5Page
This Manual
It is important that all persons supervising, operating, or servicing your Peddinghaus
Corporation Peddimat machine, read and understand this manual.
This manual deals with the mechanical operation and maintenance of your Peddinghaus
Corporation Peddimat system. Some of the features described may be for optional equipment,
which you may not have in your system.
Optional equipment will have its own manual. All pertinent manuals will be provided for the
equipment you are receiving. For information on optional equipment that is available for your
machine, contact your Peddinghaus sales representative.
WARNING:
All persons involved with the supervising, installing, operating, or servicing of your
Peddinghaus corporation Peddimat machine should wear appropriate safety glasses,
safety shoes, hard hats, and protective work gloves.
Always observe all notes on safety, and the pertinent operating and maintenance instructions.
This instruction manual, along with the Peddimat and Control Software Manuals, contain all
information required for operating and servicing the machine.
The Peddinghaus Service Department is always at your disposal to help solve technical
problems.
6Page
Peddinghaus Corporation
Peddinghaus products have been marketed throughout the world since1903.
In the years prior to 1977, these Peddinghaus products were manufactured in Germany
exclusively. In 1977 Peddinghaus Corporation, located in Bradley, Illinois, was founded and
became actively involved with the engineering, manufacturing, sales and servicing of machines
and systems for the fabrication of plate and structural steel.
Presently, Peddinghaus Corporation manufactures a wide range of manual, PC controlled, and
CNC products for the world market. Peddinghaus Corporation maintains a complete stock of
replacement parts and service technicians to service their products which are successfully sold
throughout the world market.
Peddinghaus Corporation reserves the right to improve or change product design and
specifications without prior notice. In addition, Peddinghaus Corporation assumes no
responsibility for damages, injuries or accidents caused by improper or other than normal use of
its or any related equipment.
PEDDINGHAUS CORPORATION
300 N. Washington Avenue
Bradley, Illinois 60915
Telephone: (815) 937-3800
Telefax: (815) 937-4003
7Page
Machine Identification
MODEL: _________________________________________________
SERIAL NUMBER: ________________________________________
DATE OF MANUFACTURE: ________________________________
CONTROL TYPE/NUMBER: ________________________________
DRIVE CONFIGURATION: ________________________________
ORIGINAL PURCHASER: _________________________________
Note: If spaces are blank, print this page and enter this data for your files.
8Page
Documentation
The complete set of documentation material for your machine includes:
Instruction Manual
Consisting of:
o Introduction including Machine Identification Page
o Maintenance Instructions
o Operating Instructions
Drawings
Consisting of:
o Mechanical Assembly Drawings
o Electrical Schematics
o Hydraulic and Pneumatic Schematics
o Foundation and Installation Drawings (General Arrangement)
Control Software Manual
Peddimat Software Manual
Installation instructions
Note:
The Control Software Manual and software may be delivered early or handed out during the
training classes. These manuals should be kept safe and considered part of the overall machine
documentation.
Note:
The foundation and installation drawings are sent at the time the original order is taken. These
drawings should also be kept safe and considered a part of the overall machine documentation.
Note:
The installation instructions are sent as the machine is shipped. Those instructions should be
kept with and considered part of machine documentation.
9Page
Convention For Notes, Warnings & Cautions

Notes, Warnings and Cautions used in these operating instructions are important notes on safety.
Note: Issues that apply only in some cases appear in italic notes.
Note:
Notes on operation and safety appear in a box and must be strictly observed and carried out by
the operator.
CAUTION:
Caution refers to operating and maintenance instructions that must be strictly followed to
prevent damage and destruction.
WARNING:
Warning refers to operating and maintenance instructions that must be strictly followed to
prevent injury or death to persons.
These safety instructions apply to everyone involved in the setup, operation, maintenance, and
repair of the machine and have to be read and strictly observed.
WARNING:
The machine may be put into operation only if all measures required for accident
prevention have been taken. These measures depend on the structural conditions of the
respective installation site. For this reason, we strongly recommend planning the measures
for safeguarding your system with your local professional associations.
Note:
Always keep the operating instructions in reach of the system. Make sure that the machine is
operated only by specially trained operators and in strict observation of the notes on safety and
maintenance instructions contained in this manual.
10
Page
Safety Instructions
The machine has been designed and constructed according to state-of-the-art technology and
complies with approved operational safety standards. Still, improper operation of the machine
may endanger the operator, any other persons, or their lives, or may affect the operational
integrity of the machine itself or of other material values.
Proper Use
The term proper use of the machine refers to the machining of steel plate by drilling or cutting.
Operate the machine only when it is in technically sound condition and only for performing
operations it has been designed for. Always observe all pertinent safety, operating, and
maintenance instructions laid down in this instruction manual, and be aware of potential
dangers.
Always have malfunctions that may, in any way, affect the safe operation of the machine taken
care of immediately. The term proper use explicitly includes reading of the operating
instructions and observing the pertinent inspection and maintenance instructions.
Improper Use
If the machine is improperly handled by personnel that have not been trained for its operation,
dangerous situations may arise. For this reason, the machine may be run and operated only by
trained personnel authorized to operate it. The system is exclusively designed for the machining
of steel plate by drilling or cutting. Any use of the system for purposes other than or exceeding
that specified above is considered improper. The manufacturer/supplier cannot be held
responsible for any damage resulting from such use. The risk is taken solely by the operator.
Note:
When idling, the noise level of the machine is at 70 dB(A). Due to various influences such as
material transport the noise level at the site of operation may exceed 85 dB(A). In this case,
noise-protection measures for the operator are compulsory.
WARNING:
Remove work pieces from the system only with the operating process stopped. The hazard
zone is safeguarded with the recommended safety gratings and safety circuits.
WARNING:
Never enter the hazard zone while your machine is switched on.
WARNING:
Never walk in between or on the roller transfer modules.
11
Page
General Notes on Safety

First, familiarize yourself with the machine.
Always keep the operating instructions in reach of the machine. In addition to the operating
instructions, also keep to and apply general legal rules and other mandatory standards as to
accident prevention and environmental protection.
Staff members engaged in performing work at the machine must have read the operating
instructions before starting their work, especially the sections on safety. Once they have started
their work, it may be too late. This applies in particular to personnel that perform work at the
machine only irregularly, such as equipping or servicing the machine.
Wear personal protective equipment according to company requirements or local laws! Always
observe the pertinent signs on the machine as to safety and dangers. Always keep the safety
signs on the machine in clearly legible condition.
In the case of machine or operational changes affecting safety, shut down the machine
immediately, secure it against tampering, and report the malfunction to the person or department
responsible. Never carry out any modification or redesign of the machine or fit additional
components that may affect the safety of the machine without permission of the supplier. This
also applies to the installation and adjustment of safety devices and safety valves.
Always follow the prescribed intervals of inspection and maintenance according to the operating
instructions.
Work at or operations with the machine may be carried out by reliable personnel only. Observe
the legal minimum age. Use trained and instructed personnel only. Clearly define
responsibilities for operation, equipment, maintenance, and servicing. Make sure that only
personnel instructed to do so perform operations at the machine.
Work on the electrical system may be performed by electricians or by persons trained to
perform electricians work and under supervision of an electrician only. Work on the electrical
system must be performed in keeping with the applicable rules of electrical codes.
Work on the hydraulic system may be performed by specialized personnel experienced in the
field of hydraulics only.
Spare parts must comply with the technical specifications defined by the manufacturer. This is
always the case with spare parts originally supplied by Peddinghaus Corporation.
Note:
Peddinghaus Corporation cannot be held responsible for any damage due to the use of parts,
accessories and/or special equipment that has not been originally supplied by Peddinghaus
Corporation.
12
Page
Normal Operation
Operate the machine only if all protective and safety installations (e.g. removable safety
devices, emergency devices) have been installed and are operable.
Check the machine at least once every shift for externally visible damage and irregularities! Any
changes (including changes in operation) must be reported to the person/department responsible
at once. If required, stop the machine immediately and secure it against tampering.
Before switching on the machine, verify that nobody is endangered by the starting of the
machine.
Use the machine in accordance with the operating instructions and its intended functional
purpose only.
Maintenance/ Adjustment
Always follow the recommended schedule and instructions for maintenance operations,
inspection procedures, adjustments, and replacement of parts. These operations may be
performed exclusively by expert personnel.
For all operations referring to the operation, productional adaptation, re-equipment, or
adjustment of the machine and its safety installations, as well as to inspection, maintenance, and
repair procedures, observe the machine startup and shutdown procedures described in the
operating instructions as well as the notes on maintenance.
Always safeguard the area of maintenance.
If the system is completely shut down for maintenance or repair work, it must be secured against
unexpected reactivation:
Disconnect the main power connection.

Use lockout/tag out procedures on the power switch!
Remove oil and other protective agents from the system, especially from couplings and screw
connections before starting maintenance or repair work. Never use corrosive detergents!
Always re-tighten screw connections you loosened for maintenance and repair work thoroughly.
Refer to specific assembly drawings for torques.
If safety equipment (guards, covers, e-stops, etc.) need to be removed for maintenance or repair
procedures, then they must be remounted and checked immediately after the work has been
completed.
Ensure that operating and process materials as well as replacement parts are disposed of in a
way that is not harmful to the environment.
13
Page
Special Sources of Danger

Use only original fuses with the prescribed ratings! When malfunctions occur in the electrical
power supply, switch off the system immediately, with the main disconnect located on the main
electrical enclosure, or at the power source circuit box which your company has installed for
this machine.
The electrical system must be checked periodically. Defects, such as loose connections or
charred cables must be taken care of immediately. Use lock-out/tag-out procedures when
performing this step.
Work on the hydraulic system may be performed by specialized personnel experienced in the
field of hydraulics only. The accumulator is "automatic relieving" and will be relieved when
electrical power is turned off.
Periodically check all tubes and screw connections for leakage and externally visible damage.
Eliminate any defects immediately! Oil that exits under pressure may cause severe injuries!
Lockout/ Tagout
Peddinghaus Corporation recommends the use of lockout/tagout of power sources per ANSI
Z244.1-1982 or any more recent revision or standard thereof, and CFR 1910.147 "The control
of hazardous energy [lockout/tagout]" or any more recent revision or standard thereof. It is the
customer's responsibility to provided their employees with the equipment and training to meet
those standards.
Lockout/tagout of energy sources includes pneumatic energy, hydraulic energy [including stored
energy in accumulators], and electrical energy.
14
Page
CHAPTER 2 Machine Description

Introduction
The Peddinghaus FDB1500 & FDB2500 are machines used for drilling, cutting and marking of
flat plate. The drill, torches and marker travel from side to side (Y-axis). The plate is positioned
by a full width roller controlling the feed axis (X-axis). Position can be programmed for any
selected combination of drilling, marking, and cutting. The drive mechanism permits you to
program material to be processed from the leading edge to 10 inches from the trailing edge. This
plate drop off is the result of the physical distance between the drive roll and the tool location.
Optional features
Drill unit with either 3 spindles or 1 spindle.

Burning/Marking options include any combination of three of the following:
200 amp Plasma Cutting System

400 amp Plasma Cutting System
Oxy-Fuel Torch System
Signoscript Marking Tool
15
Page
Machine Specifications
Type
Units of Measure
FDB 1500
FDB 2500
Maximum plate width
inches (mm)
60 (1500)
96 (2500)
Minimum plate width
inches (mm)
2 (50)
6 (150)
Maximum plate thickness inches (mm)
2 (50)
3 (75)
Minimum plate thickness inches (mm)
1/4 (6)
1/4 (6)
Maximum length piece

part
feet (mm)
20 (6100)
20 (6100)
Minimum length piece

part
inches (mm)
36 (900)
36 (900)
Minimum plate drop off

(trailing edge)
inches (mm)
10 (250)
10 (250)
Passline
inches (mm)
40 (1016)
40 (1016)
Work piece weight
max. pounds (kg)
8,250 (3,750)
20,125 (9150)
Maximum velocity X-axis in/min
600
600
Maximum velocity Y-axis in/min
600
600
Maximum hydraulic
pressure
1500
1500
380/415V
460/480V
230/240V*
575/600V*
380/415V
460/480V
230/240V*
575/600V*
approx. inches
113 1/2 x 77 x 221
113 1/2 x 77 x 280
(Height x Width x
Length)
approx. (mm)
(2883 x 1956 x 5614)
(2883 x 1956 x 7112)
Weight
approx. pounds (kg)
22,500 (10,225)
28,500 (12,950)
Number of drill
spindles**
------------------
1-3
1-3
Maximum drill size
inches (mm)
2 (51)
2 (51)
Power per spindle
Hp (kW)
15 (11.2)
15 (11.2)
Spindle travel
inches (mm)
11-13/16 (300)
11-13/16 (300)
Drill spindle rapid

advance speed
inches/min
(mm/min)
240 (6096)
240 (6096)
Variable feeds (per

spindle)
inches/min
(mm/min)
1 - 12 (25-300)
1 - 12 (25-300)
psi
Available voltages
Machine Dimensions
16
Page
Three spindle drill:

Spindle 1="Med." Speed RPM (Min.- Max.)
75-757
75-757
Spindle 2="Slow" Speed
RPM (Min.- Max.)
62-623
62-623
Spindle 3="Fast" Speed
RPM (Min.- Max.)
90-907
90-907
RPM (Min.- Max.)
62-623
62-623
PC controlled
Single spindle drill:
Speed
PC controlled
*with additional transformer
** Drill Spindles have #4 Morse Taper
17
Page
Major Components
Several sub-systems of the plate processing system are semi-independent in that their position
on the shop floor is flexible and may vary depending on your shop characteristics and/or they
are independent functional units manufactured by others. These sub-systems include: the main
machine, the hydraulic power unit, a plasma torch unit, entry and/or exit roller transfer, and a
dust collecting system (if supplied).
FDB1500 Exit View
Hydraulic power unit.
Plasma torch unit.
Roller transfer module.
Dust collector unit.
18
Page
Major electric motors
Drill motor.
Y-axis servo motor.
X-axis servo motor.
Hydraulic power unit motor.
19
Page
Hydraulic equipment
All hydraulic equipment is powered by the Hydraulic power unit.
Accumulators
There are two accumulators in the system.
Dump table accumulator.
System Accumulator
20
Page
Hydraulic cylinders
Left upper pinch roll

/material hold down
cylinder.
Right upper pinch roll /material hold

down cylinder.
Each of the three drill units is raised

and lowered by a hydraulic cylinder.
(A separate system provides drill bit
cooling air and oil.)
Tooling (Signoscript marker, Plasma Torch, Oxy-fuel

Torch) is raised and lowered by separate hydraulic
cylinders.
The hydraulic cylinder located on the Y-axis

carriage is the "parking cylinder". It allows the
drills to "Short Stroke" (retract just enough to
clear the material) when moving between
holes.
These two hydraulic cylinders operate the part

hold down device.
21
Page
Hydraulic cylinders continued
Two hydraulic cylinders on each side operate the dump table.

The upper (larger) cylinder raises and drops the table.
The lower (smaller) cylinder raises the dump table about 1/4 inch at the same time as the part
hold down is lowered, to hold the work for drilling.
Pneumatics
1. Regulator and
gauge
2. Filter
3. Manual
shutoff valve
4. Lubricator*
5. Main oiler
6. Filter (for air
knife)
7. Pressure
switch
8. Blow gun (not
shown)
*(additional for Signoscript motor)
22
Page
Pneumatics continued
The two air valves for the air knife are mounted on the part entry side of the machine.
The drill bit coolant system uses air and oil to

lubricate and cool the drill bits.
Also see Drill Operation.
Electrical Cabinet
Programmable
Logic Controller
(PLC)
Main disconnect
23
Page
Electrical Cabinet continued

Breaker / Motor contactors
1. Drill motor
2. Dust collector
3. X-axis servo motor
4. Y-axis servo motor
5. Hydraulic Power unit
1. Circuit breaker
2. Hour meter
3. Ground
E-stop relay
DC motor drives
1. X-axis servo
2. Y-axis servo
24
Page
Electrical Cabinet continued
AC variable speed
inverter for drill.
24VDC power supply
110V transformer for

110VAC power
25
Page
Electrical Cabinet continued - exterior of cabinet
Electrical cabinet cooler
Cable with RS232

connector for connecting
your computer with
Pedimat software to the
plate machine.
110VAC outlet for computer power (top

line).
Reset buttons. Resets for DC servo drives

(bottom line).
Main Operator
panel.
26
Page
Misc. Electrical Equipment
Y-axis limit of travel limit

switch.
Y-axis limit
switches
1. Limit of travel
switch.
2. Y-Axis "Zero"
switch.
Transformer for Oxyfuel torch igniter.

Located on Y-Axis
Carriage.
.
Y-axis
encoder.
27
Page
Misc. Electrical Equipment continued

Hydraulic Cylinder Valves
(Left To Right)
1. X-Axis Pinch/Drive Roller
solenoids, pressure adjustment
and gauge.
2. Material Hold Down
solenoids and flow
adjustments.
.
3. Dump Table Raise

solenoids.
4. Horizontal Clamp solenoids,
pressure adjustment and gauge.
Dump table solenoids, pressure

adjustment and gauge.
28
Page
Location of Emergency Stop (E-stop) Buttons
E-Stop exit side
.
.
E-Stop entry side
Main Disconnect
Main Disconnect
29
Page
CHAPTER 3 Machine Maintenance

Introduction
The Peddinghaus FDB1500 or FDB2500 must be checked, cared for, and serviced periodically.
Please observe all pertinent notes and instructions.
Should any questions arise that have not been answered in these operating instructions, please
call the Peddinghaus Service Department. You will always reach a competent contact person
under the telephone number (815) 937-3800.
You can also contact the Service Department by fax under (815)937-4003.
Maintenance Safety
WARNING:
Observe pertinent safety regulations when performing maintenance operations. If the
machine is operated by untrained personnel and not in accordance with the operating
instructions, or improperly, dangerous situations may arise. Maintenance work may be
carried out by trained operators with expert knowledge only. Always wear your personal
safety equipment (hearing protectors, safety shoes, safety gloves, etc.). Never reach into the
zones of operation and machining while the system is in operation.
Never carry out any maintenance or adjustment procedures while the machine is in
operation.
When carrying out maintenance work, always keep unauthorized persons away from the
machine.
Collect used filters in a special-refuse bin and dispose of them in a way that is not
harmful to the environment.
Collect oil in a suitable container and dispose of in a way that is not harmful to the
environment.
WARNING:
When you draw off oil at operating temperature you take the risk of scalding yourself.
Before disconnecting hydraulic pipes and carrying out work on the hydraulic power unit,
ensure that the pipes are no longer under pressure. Hydraulic oil exiting under pressure
can cause severe injuries.
Never change the adjustment of the valves.

After having completed all work, check all connections, including screw connections for
tightness without the system being under pressure.
Never forget to mount all guards and covers properly after the work has been completed.
30
Page
Lubrication Schedule
Please take particular note of the lubrication schedule, and the list of recommended lubricants.
Note:
The service life and operability of your machine depend on whether the lubrication and
maintenance schedules are observed.
Before initial startup of the machine, all lubrication points must be supplied with sufficient
lubricant. A filled grease gun must be considered part of the maintenance kit.
Check level daily.

Change fluid after first 1,000 hours of operation.
Change fluid after 2,500 hours of operation or at least annually.
Grease fittings
Lubricate every 200 hours of operation
Dump table rack and pinion
Remove covers and grease after first 1,000 hours of operation and after each 2,500 hours
of operation.
Drill spindle drive transmission
Check level monthly.

Change fluid annually.
List of Recommended Lubricants

LUBRICANT
Transmission Oil- MOBIL GEAR 629
LITHIUM ROLLER BEARING
GREASE(No Moly-Disulfide Added)
MOLYCOTE BR2 GREASE (MolyDisulfide Paste Grease)
31
Page
SPECIFICATIONS FOR STANDARD REPLACEMENT PARTS
Metric Fastener Torques
Torque induced
screw stress
screw
size
pitch
M4
0.7
tensile
area
(mm2)
8.8
M5
0.8
14.2
M6
20.1
M8
1.25
36.6
M10
1.5
58.0
M12
1.75
84.3
M16
M20
M24
M30
M36
2
2.5
3
3.5
4
157
245
353
561
817
Socket head cap screw, class 12.9

General usage
Special usage
32,000 PSI(220 Mpa)
100,000 PSI (690
Mpa)
dry
Lubed or
Loctited
dry
Lubed or
Loctited
13 in-lb
147 N-cm
27 in-lb
305 N-cm
46 in-lb
5.2 N-m
111 in-lb
13 N-m
219 in-lb
25 N-m
32 ft-lb
43 N-m
106 N-m
206 N-m
357 N-m
705 N-m
1231 N-m
10 in-lb
113 N-cm
21 in-lb
237 N-cm
35 in-lb
4.0 N-m
85 in-lb
9.6 N-m
167 in-lb
19 N-m
24 ft-lb
33 N-m
80 N-m
157 N-m
271 N-m
536 N-m
933 N-m
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
99 ft-lb
134 N-m
329 N-m
644 N-m
1113 N-m
2204 N-m
3845 N-m
76 ft-lb
103 N-m
251 N-m
489 N-m
846 N-m
1673 N-m
2914 N-m
32
Page
Metric Fastener Torques continued
Torque induced
screw stress
screw
size
pitch
M4
0.7
tensile
area
(mm2)
8.8
M5
0.8
14.2
M6
20.1
M8
1.25
36.6
M10
1.5
58.0
M12
1.75
84.3
M16
M20
M24
M30
M36
2.5
3
3.5
4
Hex head cap screw, class 10.9

General usage
w/high strength
washers
20,000 PSI (138 Mpa) 90,000 PSI (620 Mpa)
dry
Lubed or
Loctited
dry
Lubed or
Loctited
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
245
353
561
817
129 N-m
222 N-m
441 N-m
769 N-m
6 in-lb
68 N-cm
13 in-lb
147 N-cm
22 in-lb
2.5 N-m
53 in-lb
6.0 N-m
105 in-lb
12 N-m
15 ft-lb
20 N-m
37 ft-lb
50 N-m
98 N-m
169 N-m
335 N-m
583 N-m
N/A
157
8 in-lb
90 N-cm
17 in-lb
192 N-cm
29 in-lb
3.3 N-m
69 in-lb
7.8 N-m
137 in-lb
15 N-m
20 ft-lb
27 N-m
66 N-m
90 ft-lb
122 N-m
219 ft-lb
297 N-m
580 N-m
1003 N-m
1983 N-m
3463 N-m
68 ft-lb
92 N-m
166 ft-lb
225 N-m
442 N-m
763 N-m
1506 N-m
2623 N-m
Notes:
Peddinghaus uses Class 12.9 socket head cap screws (970 MPa Proof Strength) and Class 10.9
hex head cap screws (830 MPa Proof Strength).
General usage is bolting of low carbon hot rolled steel in non-fatigue applications.
Special usage and w / high strength washers is bolting of hardened steels or alloys and / or
fatigue applications. Torque is indicated on assembly drawings. Ideally, screws should be
torqued to a preload of 60-90% of the proof strength, but the maximum preload is limited by the
strength of the bolted material.
Cadmium plated screws: multiply the tabulated dry torque values by .80.
Zinc plated screws: multiply the tabulated dry torque values by 1.1.
This table does not apply to shoulder or low head screws.
33
Page
SAE Hoses
Hose
I.D.
Hose
Description
1/4
SAE 100R2 AT
3/8
SAE 100R2 AT
1/2
SAE 100R2 AT
1/2
SAE 100R12
3/4
SAE 100R2 AT
SAE 100R2 AT
SAE 100R12 AT
1 1/4
SAE 100R12 AT
1 1/2
SAE 100R4
SAE 100R4
SAE Rating:
Work / Burst
(PSI)
5,000
20,000
4,000
16,000
3,500
16,000
4,000
16,000
3,100
12,400
2,500
10,000
4,000
16,000
3,000
12,000
150
600
150
600
Min. bend
radius
(inches)
4
Type
301
301
301
77C
9.5
381
12
381
12
77C
16.5
77C
20
881
12
881
Steel Tube
Hose
O.D.
(inches)
1/4
Wall
Thickness
(inches)
0.035
3/8
0.049
1/2
0.065
3/4
0.109
0.120
ASA Rating:
Work / Burst
(PSI)
3,850
15,400
4,300
14,400
3,580
14,300
4,000
16,000
3,300
13,200
34
Page
Steel Pipe
ASTM A53 Grade B or A106 Grade B Seamless
Pipe
Size
(inches)
1/8
1/4
3/8
1/2
3/4
1
Work Burst Pressure PSI

40
3,500
20,200
--------1,700
16,200
2,300
15,600
---------
2,100
12,100
1,800
10,100
1,700
9,100
---------
---------
3 1/2
---------
---------
1,300
5,500
1 1/4
1 1/2
80 (XS)
4,800
28,000
4,350
26,400
3,800
22,500
4,100
21,000
3,500
17,600
3,500
15,900
3,000
13,900
2,800
12,600
2,500
11,000
1,600
7,400
2,400
9,500
2,300
9,000
2,090
8,100
160
---------
XXS
---------
---------
---------
---------
---------
7,300
26,700
8,500
25,000
---------
---------
4,400
18,100
---------
---------
4,600
17,500
---------
-----------------
7,200
25,300
-----------------
---------
---------
---------
---------
---------
---------
35
Page
HYDRAULIC POWER UNIT
Description
The Hydraulic Power Unit is a separate piece of machinery in that it includes its own motor,
fluid reservoir and filters. The Hydraulic Power Unit is integral to the plate machine in that the
power, control and hydraulic lines are connected to and controlled by the machine.
Hydraulic power unit.
A separate maintenance manual is included with each power unit. A schematic and bill of
material is placed in that manual.
A serial number and date of manufacturing is stamped on each reservoir top.
Pressure Adjustments
Pressure adjustments on the hydraulic power pack and the hydraulic pump are only to be made
by Peddinghaus customer service engineers or by authorized personnel. Any work of this nature
carried out by unauthorized persons will mean that the machine warranty will terminate
immediately.
Control Spring, 2 to 125 PSI, Parker #P78482
Temperature
The minimum starting temperature of the hydraulic oil is between 54 and 57 degrees (12 and 14
degrees Celsius). The standard operating temperature is approximately 120 Degrees (50 degrees
Celsius). When temperatures are low the system must be allowed to warm up for 15-30 minutes
before starting operation. This will guarantee proper functioning.
36
Page
Recommended Oil
Trouble-free operation, operational safety, and the service life of the entire hydraulic system
depend on the careful selection of the hydraulic oils.
We recommend hydraulic oils that contain active ingredients for improving the stick-slip
phenomenon, avoid disturbing depositions and cavitations, and prevent undesirable reactions of
penetrated water, in addition to additives providing improved anti-corrosion protection and
aging resistance plus reduced wear.
Note:
The hydraulic oils listed below have proven appropriate for numerous Peddinghaus systems. We
therefore recommend the use of these oils.
MANUFACTURER
OILS
Mobil DTE #24
DURO AW Oil 32
Recommended Hydraulic Fluid Specifications
Premium quality hydraulic oil with a viscosity range between 150-250 SSU (30-50 CST.) at 100
degrees F (38 degrees C). Normal operating viscosity range between 80-1000 SSU (17-180
CST.). Maximum start-up viscosity is 4000 SSU (1000 CST.). In addition, the hydraulic oil
should have maximum anti-wear properties, including rust and oxidation treatment.
Under normal operating conditions, temperature rise, and average ambient humidity, operational
life is about 2000 hours. If the neutralization number (total acid number) reaches or exceeds a
value of 2.0, the oil has become corrosive and should be changed regardless of running time.
37
Page
Hydraulic Oil Level

Check the hydraulic oil level before placing the machine into operation. This can be read at the
sight glass on the side of the power unit.
CAUTION:
The hydraulic oil level must not drop below the minimum observable fluid level of the sight
glass.
Oil level sight glass

(and thermometer).
Adding Hydraulic Oil

WARNING:
The Hydraulic Power unit must NOT be in operation when adding hydraulic oil.
1. Shut down operations and turn off the
power at the main power disconnect on
the electrical cabinet.
Use Lockout/tagout procedures.
2. Screw off the tank breather cap.

3. Fill with hydraulic oil using a funnel until
oil level is at full in the sight glass.
4. Screw the tank breather cap back on.
38
Page
About Oil and Filters

The Hydraulic Power Unit has both a high-pressure output filter and a return filter. The
replacement filter numbers are found on the filter canisters. The filter has a clogged filter
indicator that will rise when the filter is not clean.
Prior to changing the hydraulic oil, the machine must be shut off and any accumulators must be
relieved. FAILURE TO DO SO CAN CAUSE SERIOUS INJURY OR DEATH.
The first hydraulic oil change must be done after 1000 working hours (see hour meter in switch
cabinet). Future oil changes must be carried out after 2500 hours and no later than one year. The
reservoir holds 30 gallons (114 liters) of oil.
Install new filters after 1000 hours of operation and replace thereafter when a dirty filter
indicator is observed on the power unit.
The suction strainer should be cleaned at each oil change.
Hydraulic Power Unit Shutdown Procedure
The Hydraulic Power Unit must be shutdown and pressure in accumulators must be relieved
before changing hydraulic oil, changing hydraulic filters, or maintenance work on hydraulic
components.
1. Shut down operations and turn off the

power at the main power disconnect on
the electrical cabinet. Use Lockout /
tagout procedures.
2. Check that the pressure gauge

reads zero (0) pressure.
39
Page
Changing the Hydraulic Oil

Note:
Check the operating hours counter regularly. The operating hours counter is located in the main
electrical cabinet.
1. Perform the Hydraulic Power Unit Shutdown
Procedure.
2. Remove the tank breather cap and the strainer
beneath the cap.
3. Draw off old hydraulic oil using a barrel
pump and dispose of it in a way that is not
harmful to the environment.
4. Open the clean out access panels on both
sides of the tank.
5. Clean the tank.
6. Clean the oil strainers inside the tank.
7. Remove and replace the high pressure filter.
8. Remove and replace the return filter.
9. Replace the access panels.
10. Refill the tank.
40
Page
Changing the Hydraulic Power Unit Filters
1. Perform the Hydraulic Power Unit Shutdown

Procedure.
2. Check that the pressure gauge reads zero (0)
pressure.
3. Remove and replace the high-pressure filter
(3a.) and / or the return filter (3b).
41
Page
GREASE FITTINGS
About Grease Fittings

Except where otherwise specified, grease all fittings with pure lithium roller bearing grease (no
Moly-Disulfide or Graphite additives) every 200 hours with a grease gun.
WARNING
Turn off all power and follow lockout/tagout procedures before beginning any
maintenance procedure.
WARNING
Any guards or covers which must be removed for servicing must be completely re-installed
prior to machine start up.
Part exit side (non-datum)
42
Page
5.
Part exit side right (non-datum)
6.
Part exit side right (non-datum)
43
Page
8.
9.
Lead Screw
10.
Pure lithium
grease
44
Page
Y-Axis Rails
11-16 There are six linear rail bearings on the Y-axis carriage, (3) top rail, (3) bottom rail. Each
has a grease fitting.
Dump Table Cam Slots
Remove the covers on both ends of the dump table and grease the dump table gear racks, cam
slots and cylinder guides every six months.
Brush on MOLYCOTE BR2 grease.
Scrap Cart
Grease the scrap cart wheels (not shown).
45
Page
Datum Pushers
Grease the datum pushers on the entry conveyor.
Entry conveyor.
Datum pusher.
Part exit side (datum)
Part exit side (datum)
46
Page
Lead Screw
10.
Datum Rollers (Part entry side)
Most of the part entry rollers have grease fittings. Those without a fitting do not require
lubrication.
Horizontal Clamp (Part entry side)
The grease fittings for the horizontal clamp rail is under the clamp.
47
Page
Spindle Feed Cylinders

Depending on the age and model of your machine there may also be grease fittings for the
Spindle Pusher Bearings. Make sure that all spindles are in the fully retracted position. Remove the
pipe plug located right next to the Full Retract Prox. Switch on each drill spindle feed assembly to access
the grease fitting. Grease the Pusher Bearing every 1000 hours with a Lithium Sub-Base Grease
(Litholine Complex EP2). IMPORTANT: Make sure to replace the pipe plug to keep contaminates out
of the gearbox.
Drill Transmission
The drill transmission is filled with MOBIL GEAR 629 transmission oil.
Drill transmission oil level sight gauge.
Drill transmission oil fill cap.

The first oil change should occur after 500 operating hours (check at operating hours counter in
the main electrical cabinet), thereafter annually.
To change the oil, remove the drain plug (15/16 inch British Standard Parallel pipe thread) with
a hex head wrench. Refill to the center of the sight gauge (approximately 1 1/2 gallons).
48
Page
DRILL COOLANT
The Peddinghaus drill is equipped with an air-cooling system for the drill bits. A coolant
emulsion is added to the cooling air.
Coolant Emulsion
We recommend using Tri Chem "Klear Kut" soluble cutting oil. This product mixes well with
any water hardness and is well suited for machining constructional steel.
When the aforementioned product is not available, we also recommend using "MOBILMET 100
SERIES" soluble cutting oil according to the following chart:
Water Hardness
MOBILMET 100
SERIES #
Under 500ppm
S-122
500ppm or higher
S-126
MOBILMET 100 SERIES coolant is primarily used for machining ferrous materials. It is well
suited for machining constructional steel since changing of color and staining may occur with
certain alloys. It is recommended to test the coolant on the material before using it.
The concentration of the operating emulsion depends primarily on the type of machining
operation, the power required for it, and the material to be machined. For materials that are
difficult to machine, concentrations of 10:1 (10 parts water to 1 part cutting oil) have proved
suitable. In favor of good corrosion resistance properties, the concentration should be at least
30:1.
In order to guarantee proper mixing of the oil, always stir the coolant into clean water; never
proceed the other way around! If large amounts of emulsion are to be prepared, we recommend
the use of mixing devices.
WARNING: Observe the safety instructions. Wear gloves when carrying out work that
involves coolant concentrate. If it gets onto your skin, rinse affected part with water. If it
gets into your eyes, rinse thoroughly with water and seek medical care.
49
Page
Replenishing Coolant Emulsion
The coolant reservoir is mounted on the

outside of the electrical cabinet.
The coolant reservoir has a capacity of 4 gallons (15 liters) of emulsion.

To fill the reservoir:
1. Turn the locking lid and remove from tank.
2. Fill the reservoir with coolant emulsion.
3. Replace the lid.
50
Page
PNEUMATICS
Lubricators
1. Main lubricator.
2. Additional lubricator for Signoscript
motor.
Parker 18L series mist lubricators are supplied with the plate machines, part number 18L64B
with manual drain and sight gauge.
Mist Lubricator Filling
Note: Maintenance for a Parker 18L series lubricator follows. See Lubricator manufacturer's
instructions for updates and for other lubricator models.
Inlet pressure must be eliminated before fill plug is removed. SHUT OFF AIR SUPPLY and
depressurize the unit by turning the self-venting regulator to zero pressure. Fill to fill line on the
bowl with oil of 100 to 200 SSU viscosity at 100 degrees F and an aniline point greater than 200
degrees F - same as SAE No. 10(petroleum based hydraulic oils or spindle oils are good
examples). DO NOT USE OILS WITH ADHESIVES OR TACKY ADDITIVES.
COMPOUNDED OILS CONTAINING SOLVENTS, GRAPHITE, SOAPS OR
DETERGENTS (automotive oils generally contain detergents) ARE NOT RECOMMENDED.
Replace the fill plug and seat firmly (hand tight) - excessive torque is not necessary. The
lubricator is now ready for setting. Re-pressurize the lubricator.
OIL DELIVERY ADJUSTMENT - adjust oil delivery; turn the metering screw in the
top of the lubricator.
LESS OIL - Clockwise
MORE OIL - Counterclockwise
By counting the number of drops per minute in the sight dome, you can adjust your
requirements. Approximately 3% of the drops seen in the sight dome go downstream; adjust
drip rate accordingly. Consult the oil delivery conversion chart on the next page.
25 drops per minute equals one ounce (.03 liters) per hour -volume of oil passing through sight
dome.
51
Page
Note:
This is a constant density type lubricator which delivers a constant ratio of oil to air flow.
Therefore, if air flow increases or decreases, oil delivery will be adjusted proportionately.
ONLY IF A DIFFERENT RATIO IS DESIRED SHOULD YOUR METERING SCREW
SETTING BE CHANGED AFTER YOUR INITIAL SETTING.
Oil Delivery Drip Rate Chart
Your FDB1500 system has an intermittent pneumatic usage. Because of this, the lubricator is set
for a steady dripping of oil. Oil is used only on demand of air, so the oil reservoir should be
checked on a weekly basis.
52
Page
Filter Draining
Both free moisture and solids are removed automatically by the filter. There are no moving
parts.
Manual drain filters must be drained regularly before the separated moisture and oil reaches the
bottom of the lower baffle. Automatic drain models will collect and dump liquids automatically.
Note
Collect drained contaminated liquid and dispose of in an environmentally safe manner
The filter element should be removed and replaced when a working pressure of 75 psi (5 bar)
can no longer be set with the regulator.
Filter Replacement
To remove the filter element: SHUT OFF AIR SUPPLY and depressurize the unit by turning the
self-venting regulator to 0 (zero) pressure.
1. Unscrew threaded bowl.
2. Unscrew lower baffle and remove filter element and gaskets (2).
3. Clean all internal parts and bowl before reassembling. See to clean
polycarbonate bowls below.
4. Install new element and gaskets (2).
5. Attach lower baffle and tighten firmly.
6. Replace bowl seal; lubricate seal to assist in retaining it in position. Use only
mineral base oils or grease. Do NOT use synthetic oils such as esters and do
NOT use silicones.
7. Screw bowl into body.
TO CLEAN POLYCARBONATE BOWLS USE MILD SOAP AND WATER ONLY! DO
NOT USE cleaning agents such as acetone, benzene, carbon tetrachloride, gasoline, toluene,
etc., which are damaging to this plastic.
Bowl guards are recommended for added protection of polycarbonate bowls where chemical
attack may occasionally occur.
53
Page
Care and Maintenance of the Electric System

Inspections and maintenance work on the electrical and electronic systems may be performed by
trained and authorized electricians only.
Should any questions arise, please revert to the Peddinghaus Service Department. You will
always reach a competent contact person under the telephone number (815) 937-3800.
You can also contact the Service Department by fax under (815) 937-4003.
Electric Components in the Control Panel
Check the functions of the operating elements annually.

Clean all switches and components every six months.
Check all terminal connections annually.
Check and adjust control and auxiliary voltages annually.
Check the heat exchanger weekly and clean it if required. Cleaning and maintenance
work on the heat exchanger may be performed by expert personnel only.
54
Page
CHAPTER 4 Machine Operation

Introduction
Staff members engaged in performing work at the system must have read the operating
instructions when starting their work at the machine, especially the sections on safety. Once
they have started their work, it may be too late. This applies in particular to personnel that
perform work at the machine irregularly, such as equipping or servicing the system.
WARNING
Observe the pertinent safety regulations and the general notes on safety when performing
operations. If the machine is operated by untrained personnel and not in accordance with
the operating instructions, or improperly, dangerous situations may arise. Always wear
your personal safety equipment (hearing protectors, safety shoes, safety gloves, etc.).
Never reach into the zones of operation and machining while the system is in operation.
WARNING
The system may be put into operation only when adequate measures required for accident
prevention have been taken i.e. (safety covers, electrical safeguarded gates, etc.).
Daily Startup
The following steps are recommended when starting machine:
1. Check air oiler levels. (Fill if needed)
2. Check air filter/separator. (Empty if required)
3. Check hydraulic power unit oil level.
4. Clean area of drill chips.
5. Check the cleanliness of all the linear ways. Wipe off and lubricate with
Teflon or silicone spray.
6. Check the cleanliness of all exposed cylinder rods, including the horizontal
clamp, and both Y-axis guides. Also check the drill spindles, wipe off and
lubricate with Teflon or silicone spray.
7. Check the sharpness of all drill bits. Resharpen or replace as needed.
8. Turn on main power.
9. Press the "START" button on the Control Console.
55
Page
10. When the system is ready, the "E-Stop Warning" may be on the display. If so,
be sure all E-Stop switches are open and press the "E-Stop Reset" button to clear
the machine for operation.
Shutdown
The following steps should be executed in sequence when shutting down:
1. Press the "EXIT" button in the software. Answer "YES" to the "Shutdown the
entire system?" prompt. Wait for the "Safe to Shut Off Computer" message to
display.
2. Press the "OFF" button on the Control Console to shut off the power to the
machine.
Tool Changes
The software includes a provision for changing the drill-bits on the machine. Please refer to the
software manual for the location of the "Tool Change Button" in the program menus. This
button will move the Y-axis to a position that is comfortable for changing the drill-bits.
Use a drill drift to remove the bit or extension from the spindle. If an extension is used, move a
safe work area before removing the bit from the extension.
Insert the extension and/or the drill-bit into the drill spindle and tap lightly using a soft face
hammer. Always double check to be sure the drill-bits and/or extensions are secured correctly
into the drill spindle.
The drill feed rates are automatically adjusted for every single drill spindle via the P.C. Control
and require no manual adjustment
Horizontal Clamp
The horizontal clamp presses the plate against the datum line of the machine. During the
machining operation, the work piece is held in position by the X-Axis rollers.
The horizontal clamping device pressure is set by the control between 102-1500 psi (7-103 Bar)
56
Page
Smoke Collector Airflow Adjustment (for those machine with a Peddinghaus supplied dust
collector)
Smoke collector for plasma machines air flow adjustment:
The damper adjustment is made by the following technique:
Close the damper almost completely (90%). Burn metal and observe the smoke rising near the
Plasma torch. Adjust the smoke collector's damper to just capture the smoke. The damper must
be securely locked in place after adjusting. Use a tool to assist locking the damper to prevent
loosening from vibration.
1. Variations in smoke collector damper designs might require different damper
adjustments.
2. Do not adjust the damper based on percentage of "open" or" closed", as this is
not a true measure of the actual airflow. 30%closed might only be 5% reduction
of airflow.
3. Changes in duct length and construction may cause each machine installation
to have a unique damper setting.
4. As filters are used, "seasoned", the amount of damper will change. New filters
will require a more closed damper. Changing from used, "seasoned", to new
filters will require an evaluation of whether the damper airflow needs to be readjusted.
Note
Excessive airflow may cause hot sparks to enter the filter media, or cause particles to become
imbedded into the filter media. Imbedded particles will prevent filter "self cleaning" during the
purging process.
57
Page
Drill Bit Usage

Cooling duct drill-bits are used for extremely high cutting performance. The coolant emulsion is
forced through the cooling ducts under pressure. This process cools the drill bit and enhances
chip removal. Cooling duct drill bits have high operating speeds and long service life, which
makes them very economical.
For drilling without coolant, use standard HSS (High Speed Steel) drill-bits.
Changing drill bits
The software includes a provision for changing the drill-bits on the machine. Please refer to the
software manual for the location of the "Tool Change Button" in the program menus. This
button will move the Y-axis to a position that is comfortable for changing the drill-bits.
Use a drill drift to remove the bit or extension from the spindle. If an extension is used, move a
safe work area before removing the bit from the extension.
Insert the extension and/or the drill-bit into the drill spindle and tap lightly using a soft face
hammer. Always double check to be sure the drill-bits and/or extensions are secured correctly
into the drill spindle.
The drill feed rates are automatically adjusted for every single drill spindle via the P.C. Control
and require no manual adjustment.
58
Page
Defects on Drill-Bits and their Most Frequent Causes

Excessive cutting speed.
Defect causing outer edges to break off
Hardened spots in the material.

Cutting flutes clogged with chips.
Cutting edges chip

Tears in the cutting edges
Excessive feed.
Excessive back relief angle on the cutting edge.
Stress cracking due to overheating or too rapid
cooling during regrinding or drilling.
Drill-bit ground incorrectly.
Drill swings out of direction
Excessive feed.
Drill-bit is blunt.
Cutting flutes clogged with chips.
Drill-bit breaks
Drill-bit is split right through the center
Incorrect fitting between tapered shaft and chuck

due to dirt or chips.
Relief angle too small.
Excessive feed.
Drill-bit is blunt.
Drill-bit does not catch
Relief angle too small.

Core too strong.
Bored hole has a rough surface
Drill-bit is incorrectly ground.
Bore is too large
Cutting edge angles or cutting edge lengths are not

identical, or both.
Chip form changes during the drilling

operation
Drill-bit is becoming blunt or the cutting edges

have chipped.
Large chip from one cutting flute, small

chip from the other cutting flute
Drill-bit incorrectly ground, one cutting edge is

doing all the work.
59
Page
Drill Coolant System
The Drill coolant emulsion tank is mounted

on the main electrical cabinet.
The emulsion is pumped by an air pump.
1. Air supply to
power pump.
2. Air pump.
3. Emulsion
flow
adjustment.
4. Emulsion
return to tank.
5. Emulsion to
drill bits.
6. Emulsion
from tank.
The emulsion is
combined with
coolant air.
7. Emulsion from
air pump.
8. Air supply.
9. Air adjustment
valve.
10. Coolant air /
emulsion to drill
bits.
60
Page
SIGNOSCRIPT MARKER
About the Signoscript Marker
The Plate Machine is optionally shipped with a Signoscript Marker. The Peddinghaus
Signoscript Marker system uses a pneumatic motor to drive a carbide insert cutter. Control of
the X and Y axis using Peddimat software lets you mark or scribe your parts as needed.
Shown here on the far left is the Signoscript
Marker - next to a plasma torch and oxyfuel torch in this optional tool
configuration.
Marker Service
The cutter and its holders can be accessed by removing the Marker's cup. This is done by
releasing the two clamps that hold it onto the knurled adjustment nut.
Marker with marker cup

removed.
The Marker's pneumatic motor is held in place with a nut and ferrule (2). By loosening the nut
with a spanner wrench (supplied), the motor can be removed.
61
Page
Air motor with cutter bit.
The cutter's tool holder is held in the motor by a collet (3). Removing it requires a 1-inch and
5/8 inch thin head wrench (supplied).
Removing the insert cutter from the tool holder requires an insert cutter wrench along with a
5mm Allen wrench (both supplied).
Insert tool
Carbide insert cutter
62
Page
Marker Adjustment
Initial Cutter adjustment
Initially, set the knurled adjuster nut so that there is about 1/4inch adjustment above the adjuster
nut as shown below.
Then, with the carbide cutter firmly tightened into the cutter's tool holder, slide the tool holder
into the pneumatic motor's collet until there is 7 inches from the bottom of the cutter to the
bottom of the adjuster nut as shown. Tighten the collet. This will set the cutter to zero cutting
depth.
Fine Adjustment
The depth of the cut for the marker is set by turning the knurled adjuster (1). One full turn
corresponds to 1/16 inch in cutter depth. Each of the four lines scribed in the top of the adjuster
nut adjusts the cutter depth by 1/64 inch. Turning the adjuster nut to the right increases the
cutter depth while turning to the left decreases it.
Character Width
With the 90 deg carbide insert cutter installed in the marker (standard with marker option) an
incremental increase in cutter depth will result in an increase of two times that change in
character width.
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PLASMA TORCH
About the Plasma Torch
The Plate Machine is optionally shipped with a Hypertherm Plasma Torch for cutting. The
principle of Plasma-Arc Cutting uses a high velocity jet of hot ionized gas to cut the material. In
order to produce the best possible cuts (least bevel and correct sizing) during Plasma-Arc
cutting the guidelines on the following pages should be used.
Plasma torch shown as center tool in

optional configuration including
Signoscript marker, Plasma torch and Oxyfuel torch.
Torch Tip Adjustment

Torch tip standoff height adjustments are made in the software, see the torch manual for
requirements.
The only mechanical setting is the torch tip is set so it is1/32 inch above the bottom level of the
plasma torch cup. To make this setting move the tooling to tool change position, turn off and
lock out power, and be sure the tooling has been allowed to cool. Open the clips (1), and remove
the plasma torch cup. Loosen the nut (2) so the plasma torch height can be adjusted but retains
its position. Replace the plasma torch cup to check the height. When correct, remove the plasma
torch cup and tighten the nut (2). Replace the plasma torch cup.
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Torch Path Routing

The cut produced by a Plasma Torch has a "good side" (approx. 2 to4 degree bevel*) and a
"bevel side" (approx. 7 to 9 degree bevel*).The placement of these sides in relationship to the
torch travel is dependent on the "Swirl Ring" direction (clockwise is standard). All"
Peddinghaus" equipment is supplied with the standard "Clockwise Swirl Ring".
*Depending on the plasma torch model used.
What this will produce is the "Good Side" or "Square side" of the kerf (see page 17 for fuller
treatment of kerf) to the right of the torch when viewed from behind. This data must be taken
into consideration when programming parts to be run on an "FDB" machine in order to achieve
the best finished parts possible.
Correct Torch-Travel Direction For Various Cut-Offs
Straight Cut-Off Or Single Trim Cut: "Good" side will be to the right side of torch-travel (or
part trailing edge) when cutoff is performed from the datum side to non-datum side. See left
illustration below.
If leading edge is desired to be "good" side, then cut off must be performed from non-datum
side to datum side. See illustration right illustration above.
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Making A Double Trim Cut: A double trim cut is a cutoff made with the torch traveling from
the datum side to the non-datum side, followed by a cutoff from the non-datum side to the
datum side. Since the "good" side of the kerf is to the right of the direction of torch-travel, this
results in both pieces having the "good" edges, one being the "trailing edge" of the completed
part and the other being the "leading" edge of the part in process. Peddinghaus Engineering
specifies the width of a double trim cut to be 1/2"(13mm) for material under 3/4" (19mm) thick,
and 3/4" (19mm) for material over 3/4" (19mm) thick, up to 1 1/4" (32mm) thick maximum. See
illustration below.
Cutting A Hole With Nearly Square Sides: Cut must be made with the torch traveling counter
clockwise. In this case, the hole will have the "good" side edge. See illustration below.
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Cutting A Circular Plate (Disk) with Nearly Square Sides: Cut must be made with the torch
traveling clockwise. In this case, the disk will have the "good" side edge. See illustration below.
Correct torch travel directions for various cut-offs: Summary illustration below.
Plasma Torch - Kerf & Cutter Compensation Definitions &Data
The term Kerf refers to the gap that is removed as molten metal during the cutting
process. This gap is approx. 1/8" and should be verified by the operator when the
material thickness changes and then entered into "Peddimat" as the "Saw or Shear Kerf"
in the "Machine Offsets" section of software status.
The term "comp." refers to "cutter radius compensation" performed by the Fagor CNC.
This compensation shifts the actual path of the torch left or right of the theoretical torch
path. The shift amount is half of the Kerf dimension entered in Peddimat. (See
Illustration below). IT IS IMPORTANT THAT THE KERF DIMENSION ENTERED
IS ACCURATE.
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With cutter compensation disabled, custom burns produced by the machine will be
undersized or oversized by half the torch Kerf, depending upon the direction of torch
travel.
If cutter comp. is set to the correct side of the torch, (left for standard swirl ring) the
actual torch path would be offset into the scrap portion of the material. This would cause
custom burns to be correct.
If cutter comp. is set to the wrong side of the torch, (right instead of left for example) the
actual torch path would be offset into the finished part instead of the scrap portion of the
material. This would cause custom burns to be under or oversize by the full Kerf value.
Optional Kerf Changes

To obtain optimum edge-cut quality and very accurately sized cut parts determine optimum Kerf
parameters by making successive cut/Kerf checks, and recording this Kerf value. Change the
default kerf setting in "Peddimat" to this newly determined value.
The Kerf created by plasma burning is a function of many variables, including the feed
rate, material thickness, torch to work distance, gas-pressure settings, amperage setting,
and the condition of the consumables.
The feed rate, pressure settings, and amperage setting should remain constant depending
on the material thickness being run.
The condition of the consumables should only change the resulting Kerf very slightly
and should not be a factor.
If very accurate and high-quality-edged plasma cut parts must be produced, it is
recommended that a "Kerf Chart" be developed & kept by the operator listing the
optimum Kerf to be used based on the material thickness to be cut.
This may be accomplished by making successive material cut-offs and checking the
resulting edges, prior to making any production parts. The edge-cut parameters to check
should include:
o Full Penetration (primarily a function of Torch-to-work off-set distance,
amperage, and feed rate settings).
o Edge squareness: check that maximum bevel is made on scrap; not good part
(primarily a function of correct torch travel/routing).
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o
o
Quality of cut: clean edge with minimum gouges and top and bottom dross
formation (primarily a function of the condition of consumables, Torch-to-work
off-set, feed rate, gas pressure and amperage settings).
Once the above edge-cut parameters are considered satisfactory for production
parts, the operator should make a number of straight cuts partly into the material
from an edge, using all the same settings which produced the satisfactory edgecut previously. The operator should measure and record the Kerf (gap size)
dimension produced on the "Kerf chart" In addition, the "amperage", "gas
pressures", and "feed rate" settings should also be recorded on the "Kerf chart"
for future production use of these settings to obtain optimum results when
plasma-cutting parts from the same type and thickness of material.
THIS PROCESS SHOULD BE REPEATED FOR ALL MATERIAL
THICKNESSES REQUIRING THE SAME DEGREE OF QUALITY AND
ACCURACY OF PRODUCTION PARTS.
This experimentally determined optimum Kerf dimension must be entered into
Peddimat in order to achieve the optimum quality production parts required.
Creation and use of chart(s) showing a history of Kerf sizes (based on material
thickness) will help to make future Kerf selection, and entry into Peddimat
correct, therefore, correct part sizes will result. Without this Kerf information, an
average (default) Kerf setting must be used, possibly resulting in the part size
changing as the Kerf changes.
Summary Notes
Producing accurately sized plasma-arc cut parts with high quality cuts requires all of the
following:
The part must be programmed correctly. The torch must be routed so its path will put the
required "good side" of cut to the right of the torch when viewed from behind the torch
as it burns.
The correct Kerf (based on the material thickness to be run) must be entered into
Peddimat. Also, the amperage and gas settings should match the settings used when the
Kerf was checked. (At time of "Kerf Table" creation).
The correct "Comp." (Left) must be selected in Peddimat.
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OXY-FUEL TORCH
General Safety Information
A number of inherent hazards exist in the use of oxy-fuel welding and cutting apparatus. It is,
therefore, necessary that proper safety and operating procedures are understood prior to using
such apparatus. Read this information thoroughly and carefully before attempting to operate
oxy-fuel welding, cutting and heating apparatus. A thorough understanding of the proper safety
and operating procedures minimizes the hazards involved and adds to the pleasure and
efficiency of your work.
The following preliminary safety checklist is the basis for further specific safety information
noted throughout this manual.
The Work Area
The work area must have a fireproof floor. We recommend concrete floors.
Use heat-resistant shields to protect nearby walls or unprotected flooring from sparks
and hot metal.
Maintain adequate ventilation to prevent the concentration of oxygen/fuel gas,
flammable gases and/or toxic fumes. It is important to remember that oxygen itself will
not burn. The presence of pure oxygen, however, serves to accelerate combustion and
causes materials to burn with great intensity. Oil and grease in the presence of oxygen
can ignite and burn violently.
During oxy-fuel processes, use work benches or tables with fireproof tops. Fire bricks
commonly top these surfaces and support the work.
Chain or otherwise secure oxygen and fuel gas cylinders to a wall, bench, post, cylinder
cart, etc. This will protect them from falling and hold them upright.
Protective Apparel
Protect yourself from sparks, flying slag, and flame brilliance at all times. Wear goggles
with tempered lenses shaded 4 or darker to protect eyes from injury and to provide good
visibility of the work.
Wear protective gloves, sleeves, aprons and shoes to protect skin and clothing from
sparks and slag. Keep all clothing and protective apparel absolutely free of oil or grease.
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Fire Prevention
Practice fire prevention techniques whenever oxy-fuel operations are in progress. A few simple
precautions prevent most fires and minimize damage in the event a fire does occur. Always
practice the following rules and safety procedures.
Inspect oxy-fuel apparatus for oil, grease or damaged parts. DO NOT use the oxy-fuel
apparatus if oil or grease is present or if damage is evident. Have the oxy-fuel apparatus
cleaned and/or repaired by a qualified repair technician before using it.
Never use oil or grease on or around any oxy-fuel apparatus. Even a trace of oil or
grease can ignite and burn violently in the presence of oxygen.
Keep flames, heat and sparks away from cylinders and hoses.
Flying sparks can travel as much as 35 feet. Move combustibles a safe distance away
from areas where oxy-fuel operations are performed.
Use approved heat-resistant shields to protect nearby walls, floors and ceilings.
Have a fire extinguisher of the proper type and size in the work area. Inspect it regularly
to ensure that it is in proper working order. Know how to use it.
Use oxy-fuel equipment only with the gases for which it is intended.
DO NOT open an acetylene cylinder valve more than approximately 1 1/2 turns and
preferably no more than 3/4 of a turn. Keep the cylinder wrench, if one is required, on
the cylinder valve so the cylinder may be turned off quickly if necessary.
All gases except acetylene: Open the cylinder valve completely to seal the cylinder
back seal packing.
Never test for gas leaks with a flame. Use an approved leak-detector solution.
When work is complete, inspect the area for possible fires or smoldering materials.
Vision Safety
NEVER LOOK DIRECTLY AT THE FLAME. WEAR GOGGLES WITH
TEMPEREDLENSES SHADED 4 OR DARKER TO PROTECT EYES FROM INJURY
AND TO PROVIDEGOOD VISIBILITY OF THE WORK.
Also, WARN other people in the area NOT TO LOOK DIRECTLYAT THE FLAME, unless
they wear proper eye protection.
For complete eye safety instructions (including recommended lens shade #'s) and other safety
requirements & warnings, be sure to read and follow "Section 1: General Safety Information" of
the "Victor Oxy-Fuel Welding, Cutting and Heating Guide" (latest revision) which has been
excerpted above and a copy of which is supplied with each machine.
Caution:
If the FDB1500 will be located in an area where the cutting section of the machine will be
directly visible to other persons in the area, Peddinghaus Corporation recommends installing
protective screens or curtains to prevent any inadvertent eye exposure of other workers or
persona passing by.
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Gas Control Panel

The Oxy-fuel torch gas control panel regulates the fuel and Oxygen to the Oxy-fuel torch.
Contents:
1. FUEL HIGH controls
2. FUEL LOW controls
3. CUT OXY gauge
4. OXY HIGH controls
5. OXY LOW controls
6. CUT OXY controls
Note: Also see "Victor Oxy-Fuel Welding, Cutting and Heating Guide" for descriptions and
functional operation of regulators, needle valves and inlet/outlet connections.
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Gas Control Panel Continued

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

1a. Regulator
1b. Gauge
1c. Flow Control Valve
This further regulates the incoming cutting fuel supply to the Peddinghaus "High" pressure
setting. Fuel high is used primarily for fast pre-heating and to add a boost when first starting a
cut at an edge or piercing. This regulator may be set up to 25% higher than(2), the Low Pressure
Incoming Fuel Regulator. The setting used is dependent on the cutting gas used, tip size and
material to be cut.
WARNING:
The supply pressure of acetylene gas to the gas control panel should never exceed 15 psi (105 KPa).
73
Page

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

2a. Regulator
2b. Gauge
This further regulates the incoming cutting fuel supply. The setting depends on the fuel used,
torch tip used, and plate thickness. (See Oxy-Torch Cutting Charts for suggested FUEL LOW
pressure settings.)
CUT OXY gauge
3. CUT OXY Gauge

Main cutting Oxygen monitoring gauge. This gauge indicates the Oxygen pressure available at
the torch tip for cutting operations.
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Page

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

4a. Regulator
4b. Gauge
This further regulates the incoming cutting oxygen supply to the Peddinghaus "High" pressure
setting. It is used primarily for fast pre-heating and piercing (cut-starting applications). This
regulator may be set up to 25% higher than (5), the OXY LOW pressure incoming oxygen
regulator.
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OXY LOW controls
5. OXY LOW - Incoming low pressure pre-heat Oxygen controls.

5a. Regulator
5b. Gauge
This further regulates the Incoming Oxygen Supply. . The setting used is dependent on the
cutting gas used, tip size and material to be cut. (See Oxy-Torch Cutting Charts for suggested
OXY LOW pressure settings.)
CUT OXY controls
6. CUT OXY controls - Main cutting Oxygen controls.

6a. Regulator
6b. Gauge
Regulates the pneumatic pilot circuit, which then controls the cutting oxygen pressure. The
setting used is dependent on the cutting gas used; tip size and material to be cut. (See OxyTorch Cutting Charts for suggested CUT OXY pressure settings.)
76
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OXY-FUEL TORCH - OXY-TORCH OPERATING GUIDELINES

Pre-Operation
Ensure that your cutting environment and your clothing meet the safety requirements.
Refer to Oxy-Torch Cutting Charts for the type and thickness of material you plan to cut.
Select the gas combination that will create the desired results.
Check to see if your gas supplies are adequate for the amount of cutting to be done.
Select the proper torch tips from the Cutting Chart Data. See Oxy-Torch Cutting Charts.
Install the tips in the torch. (See Torch Tip Cleaning and Changing Procedure.)
Operation
When the part is programmed with Peddimat Software, the cutting speeds are automatically sent
to the Fagor CNC controller.
The cutting speed may be adjusted by changing the Fagor Feed rate Adjustment.
Set the torch spacing with the work piece (per spacing adjustment procedure; below.)
Torch Spacing Adjustment:
Turn adjusting collar (1) to adjust the spacing (2)
between the torch tip end and the ignitor.
Set the torch tip 1/8" above the bottom level of the
ignitor (2) (one ignitor shown).
(Note: The ignitor(s) also serve as a material
sensing foot).
Torch lighting:
The torch is lit using a 120V primary / 10,000V secondary ignition transformer. The transformer
supplies 10,000 volts to the torch. When it jumps from the torch tip to ground, it creates a spark
to light the gases. The voltage goes to a grounding electrode (igniter), which also serves as a
material sensing foot (one igniter shown above). These grounding locations should be kept clean
and at a distance of1/4 inch (6 mm) minimum to 1/2 inch (13 mm) maximum from the torch tip.
WARNING:
Keep clear of these locations during the torch lighting sequence.
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OXY-TORCH CUTTING CHARTS

Cutting Chart Data Introduction (Mild Steel)
The Peddinghaus FDB1500 machine can use a variety of different fuel gases to cut steel. Some
of these different gases are:
Acetylene
Natural Gas
Propane
Chem-O-Lene
Butane
Flamex
Liquid Air
MAPP Gas
Propylene
Apachi Gas
B-Plus
H.P.G.
RD
T-9
Ucon 96
FG-2
Cutting tips
All the cutting tips used are General purpose, Medium preheat type. The overall length of the
cutting tip is 76mm (3").
Cutting Charts
The following cutting charts are a guide for pressure settings, tip sizes, cutting speeds, kerf
width, etc. Start by finding the fuel gas and the tip model being used. (This is only a guide,
settings are approximate only.)
Note:
Torches for acetylene must use "extreme duty mixer". This is now standard on all torches.
Change to "standard duty mixer" when using any other gas.
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Oxy-Fuel Torch - Oxy-Torch Cutting Charts

ACETYLENE: MODEL 1-101 (ONE PIECE TIPS)
Max. Thk.
Tip Size
Tip #
6mm (1/4")
00
YD2304550
13mm (1/2")
YD2304120
19mm (3/4")
YD2304119
38mm (1-1/2")
YD2304064
63mm (2-1/2")
YD2304627
Thickness
Oxygen
Oxygen
Fuel
(CUT OXY) (OXY LOW) (FUEL LOW)
Speed
Kerf
6mm
1/4"
140/170 kPa 20/35 kPa

20/25 psi
3/5 psi
20/35 kPa 70/75 cm/m 1,3mm

3/5 psi
27/30 ipm 0.05"
10mm
3/8"
170/210 kPa 20/35 kPa

25/30 psi
3/5 psi
20/35 kPa 60/70 cm/m 1,5mm

3/5 psi
24/28 ipm 0.06"
13mm
1/2"
210/240 kPa 20/41 kPa

30/35 psi
3/6 psi
20/35 kPa 50/60 cm/m 1,5mm

3/5 psi
20/24 ipm 0.06"
19mm
3/4"
210/240 kPa 27/48 kPa

30/35 psi
4/7 psi
20/35 kPa 43/53 cm/m 1,8mm

3/5 psi
17/21 ipm 0.07"
25mm
1"
240/275 kPa 27/55 kPa

35/40 psi
4/8 psi
20/41 kPa 38/48 cm/m 2,3mm

3/6 psi
15/19 ipm 0.09"
51mm
2"
275/310 kPa 35/70 kPa

40/45 psi
5/10 psi
27/55 kPa 30/38 cm/m 2,8mm

4/8 psi
12/15 ipm 0.11"
79
Page

NATURAL GAS and PROPANE: MODEL 1-200 (ONE PIECE TIPS)
Max. Thk.
Tip Size
Tip #
6mm (1/4")
00
YD2304549
13mm (1/2")
YD2304196
19mm (3/4")
YD2304391
38mm (1-1/2")
YD2304631
63mm (2-1/2")
YD2304632
Thickness
Oxygen
(CUT OXY)
Oxygen
Fuel
(OXY LOW) (FUEL LOW)
Speed
Kerf
6mm
1/4"
140/170 kPa 135/170 kPa 20/35 kPa 53/63 cm/m 1,3mm

20/25 psi
20/25 psi
3/5 psi
21/25 ipm 0.05"
10mm
3/8"
170/210 kPa 135/170 kPa 20/35 kPa 50/60 cm/m 1,5mm

25/30 psi
20/25 psi
3/5 psi
20/24 ipm 0.06"
13mm
1/2"
210/240 kPa 135/170 kPa 20/35 kPa 45/55 cm/m 1,5mm

30/35 psi
20/25 psi
3/5 psi
18/22 ipm 0.06"
19mm
3/4"
210/240 kPa 135/170 kPa 27/41 kPa 38/50 cm/m 2,0mm

30/35 psi
20/25 psi
4/6 psi
15/20 ipm 0.08"
25mm
1"
240/275 kPa 135/170 kPa 27/55 kPa 35/45 cm/m 2,3mm

35/40 psi
20/25 psi
4/8 psi
14/18 ipm 0.09"
38mm
1-1/2"
275/310kPa 135/170 kPa 35/62 kPa 30/40 cm/m 2,3mm

40/45 psi
20/25 psi
5/9 psi
12/16 ipm 0.09"
51mm
2"
275/345 kPa 135/170 kPa 35/62 kPa 23/35 cm/m 2,5mm

40/50 psi
20/25 psi
5/9 psi
10/14 ipm 0.10"
80
Page

LIQ. AIR, MAPP GAS and PROPYLENE: MODEL 1-303MP (ONE PIECETIPS)
Max. Thk.
Tip Size
Tip #
6mm (1/4")
00
YD2304548
13mm (1/2")
YD2304410
19mm (3/4")
YD2304411
38mm (1-1/2")
YD2304611
63mm (2-1/2")
YD2304636
Thickness
Oxygen
(CUT OXY)
Oxygen
Fuel
Speed
Kerf
6mm
1/4"
140/170 kPa 135/170 kPa 20/35 kPa 53/63 cm/m 1,3mm

20/25 psi
20/25 psi
3/5 psi
21/25 ipm 0.05"
10mm
3/8"
170/210 kPa 135/170 kPa 20/35 kPa 50/60 cm/m 1,5mm

25/30 psi
20/25 psi
3/5 psi
20/24 ipm 0.06"
13mm
1/2"
210/240 kPa 135/170 kPa 20/35 kPa 45/55 cm/m 1,5mm

30/35 psi
20/25 psi
3/5 psi
18/22 ipm 0.06"
19mm
3/4"
210/240 kPa 135/170 kPa 27/41 kPa 38/50 cm/m 2,0mm

30/35 psi
20/25 psi
4/6 psi
15/20 ipm 0.08"
25mm
1"
240/275 kPa 135/170 kPa 27/55 kPa 35/45 cm/m 2,3mm

35/40 psi
20/25 psi
4/8 psi
14/18 ipm 0.09"
38mm
1-1/2"
275/310kPa 135/170 kPa 35/62 kPa 30/40 cm/m 2,3mm

40/45 psi
20/25 psi
5/9 psi
12/16 ipm 0.09"
51mm
2"
275/345 kPa 135/170 kPa 35/62 kPa 23/35 cm/m 2,5mm

40/50 psi
20/25 psi
5/9 psi
10/14 ipm 0.10"
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Page

LIQ. AIR and MAPP GAS: MODEL GMP (TWO PIECE TIPS)
Max. Thk.
Tip Size
Tip #
6mm (1/4")
00
YD2306847
13mm (1/2")
YD2306848
19mm (3/4")
YD2306849
38mm (1-1/2")
YD2306850
63mm (2-1/2")
YD2306851
Thickness
Oxygen
(CUT OXY)
Oxygen
Fuel
Speed
Kerf
6mm
1/4"
140/170 kPa 135/170 kPa 20/35 kPa 53/63 cm/m 1,3mm

20/25 psi
20/25 psi
3/5 psi
21/25 ipm 0.05"
10mm
3/8"
170/210 kPa 135/170 kPa 20/35 kPa 50/60 cm/m 1,5mm

25/30 psi
20/25 psi
3/5 psi
20/24 ipm 0.06"
13mm
1/2"
210/240 kPa 135/170 kPa 20/35 kPa 45/55 cm/m 1,5mm

30/35 psi
20/25 psi
3/5 psi
18/22 ipm 0.06"
19mm
3/4"
210/240 kPa 135/170 kPa 27/41 kPa 38/50 cm/m 2,0mm

30/35 psi
20/25 psi
4/6 psi
15/20 ipm 0.08"
25mm
1"
240/275 kPa 135/170 kPa 27/55 kPa 35/45 cm/m 2,3mm

35/40 psi
20/25 psi
4/8 psi
14/18 ipm 0.09"
38mm
1-1/2"
275/310kPa 135/170 kPa 35/62 kPa 30/40 cm/m 2,3mm

40/45 psi
20/25 psi
5/9 psi
12/16 ipm 0.09"
51mm
2"
275/345 kPa 135/170 kPa 35/62 kPa 23/35 cm/m 2,5mm

40/50 psi
20/25 psi
5/9 psi
10/14 ipm 0.10"
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Page

NATURAL GAS, PROPANE, CHEM-O-LENE, BUTANE, and FLAMEX: MODEL GPN
(TWO PIECE TIPS)
Max. Thk.
Tip Size
Tip #
6mm (1/4")
00
YD2304717
13mm (1/2")
YD2304718
19mm (3/4")
YD2304719
38mm (1-1/2")
YD2304720
63mm (2-1/2")
YD2304721
Thickness
Oxygen
(CUT OXY)
Oxygen
Fuel
Speed
Kerf
6mm
1/4"
140/170 kPa 135/170 kPa 20/35 kPa 53/63 cm/m 1,3mm

20/25 psi
20/25 psi
3/5 psi
21/25 ipm 0.05"
10mm
3/8"
170/210 kPa 135/170 kPa 20/35 kPa 50/60 cm/m 1,5mm

25/30 psi
20/25 psi
3/5 psi
20/24 ipm 0.06"
13mm
1/2"
210/240 kPa 135/170 kPa 20/35 kPa 45/55 cm/m 1,5mm

30/35 psi
20/25 psi
3/5 psi
18/22 ipm 0.06"
19mm
3/4"
210/240 kPa 135/170 kPa 27/41 kPa 38/50 cm/m 2,0mm

30/35 psi
20/25 psi
4/6 psi
15/20 ipm 0.08"
25mm
1"
240/275 kPa 135/170 kPa 27/55 kPa 35/45 cm/m 2,3mm

35/40 psi
20/25 psi
4/8 psi
14/18 ipm 0.09"
38mm
1-1/2"
275/310kPa 135/170 kPa 35/62 kPa 30/40 cm/m 2,3mm

40/45 psi
20/25 psi
5/9 psi
12/16 ipm 0.09"
51mm
2"
275/345 kPa 135/170 kPa 35/62 kPa 23/35 cm/m 2,5mm

40/50 psi
20/25 psi
5/9 psi
10/14 ipm 0.10"
83
Page

PROPYLENE, APACHI, B-PLUS, H.P.G., RD, T-9, UCON96, FG-2:
MODEL GPP (TWO PIECE TIPS)
Max. Thk.
Tip Size
Tip #
6mm (1/4")
00
YD2306855
13mm (1/2")
YD2306856
19mm (3/4")
YD2306857
38mm (1-1/2")
YD2306858
63mm (2-1/2")
YD2306859
Thickness
Oxygen
(CUT OXY)
Oxygen
Fuel
Speed
Kerf
6mm
1/4"
140/170 kPa 135/170 kPa 20/35 kPa 53/63 cm/m 1,3mm

20/25 psi
20/25 psi
3/5 psi
21/25 ipm 0.05"
10mm
3/8"
170/210 kPa 135/170 kPa 20/35 kPa 50/60 cm/m 1,5mm

25/30 psi
20/25 psi
3/5 psi
20/24 ipm 0.06"
13mm
1/2"
210/240 kPa 135/170 kPa 20/35 kPa 45/55 cm/m 1,5mm

30/35 psi
20/25 psi
3/5 psi
18/22 ipm 0.06"
19mm
3/4"
210/240 kPa 135/170 kPa 27/41 kPa 38/50 cm/m 2,0mm

30/35 psi
20/25 psi
4/6 psi
15/20 ipm 0.08"
25mm
1"
240/275 kPa 135/170 kPa 27/55 kPa 35/45 cm/m 2,3mm

35/40 psi
20/25 psi
4/8 psi
14/18 ipm 0.09"
38mm
1-1/2"
275/310kPa 135/170 kPa 35/62 kPa 30/40 cm/m 2,3mm

40/45 psi
20/25 psi
5/9 psi
12/16 ipm 0.09"
51mm
2"
275/345 kPa 135/170 kPa 35/62 kPa 23/35 cm/m 2,5mm

40/50 psi
20/25 psi
5/9 psi
10/14 ipm 0.10"
84
Page
Oxy-Fuel Torch - Kerf Definition and Size Range

Definition:
Kerf: Slit made in work piece by cutting torch.
Note: The actual kerf created during torch cutting is a function of many variables such as
cutting speed, torch stand-off height, torch-to-work angle, cutting gas quality and pressure
settings, type and uniformity of material being cut, amount of play in machine axes transporting
the material and torch, etc. However, once all settings and adjustments have been made, the
kerf obtained should be fairly consistent for similar cuts in same material.
Kerf Size Range:
See Oxy-Torch Cutting Charts.
Oxy-Fuel Torch - Cutting and Piercing Information
Cutting:
When cutting, make sure that the sparks are coming out of the bottom of the work piece.
If not, check for the following:
o If the sparks are spraying on top of the work piece, the torch may be moving too
fast. Check the Cutting Charts for the correct travel speeds. The optimum travel
speed is generally just slightly under the speed that causes the arc to "rooster tail"
off of the bottom of the work piece.
o If there is not sufficient pre-heat time to fully penetrate the work piece, increase
the pre-heat time. If this does not work, stop cutting and re-check the cutting
chart specifications and the torch gas and oxygen settings.
Fundamentals of Cutting
Preheat
Cutting Oxygen:
o 99.5% Minimum Purity
o (-10% Speed For Each .1% Impurity)
85
Page
Oxy-Fuel Torch - Cutting and Piercing Information Continued

Common Cutting Faults
Improper nozzle preheat selection.

Improper bore size for plate.
Improper cutting oxygen pressure.
Improper preheat level.
Improper tip to work distance
Improper cutting speed.
Poor set-up.
o Regulator improper*
o Wrong hose size*
o Wrong valve sizes*
o Poor hose splices/nipples*
o Improper torch selection
*Common problem with heavy cutting

Factors Affecting Cut Quality
Preheat settings
Oxygen bore size
Oxygen bore imperfections
Oxygen impurity
Oxygen supply pressure
Oxygen pressure
Cutting speed
Surface condition
Inclusions
Alloy elements
Piercing:
No special settings are required for piercing. Peddimat program takes care of this parameter.
Common Piercing Faults:
The work piece is NOT totally penetrated. Causes can be:

o Pre-heat time is too short.
o The cut speed is too high.
o The torch tip is worn or clogged.
o The metal being cut is too thick for the tip being used.
86
Page
Oxy-Fuel Torch - Torch Tip Cleaning and Changing Procedure

Torch tip must be checked and cleaned on a regular basis.
WARNING:
Always unplug the power supply before inspecting or changing the torch tip. Also, parts
may be hot. Wear suitable gloves and exercise caution when handling to prevent possible
burns. Refer to safety instructions before proceeding
To Clean the Torch Tip:
Position the torch in a location that allows easy reach for cleaning and inspection.
Shut off the machine. Do not enter the machine area without first disconnecting the
power supply.
USE CAUTION! If the machine has been in operation, some machine parts and scrap
may be hot. (Tips Get Hot!!)
Use a regular torch cleaning set and clean the tip. Look for splatter on the tip. Unusual
wear or marks on the tip, etc. (See Victor Oxy-Fuel Welding, Cutting & Heating Guide,
provided with each machine. Note All "Warning" & "Caution" Information.)
To Replace the Torch Tip:

1. Position as described above. Disconnect the
machine from power.
2. Use a 1" (26mm) wrench to hold the "torch body"
(a) and a 1 1/8" (29mm) wrench to loosen the "Tip
Coupling Nut" (b). Be careful not to drop the tip.
3. Fit new torch tip into "Tip Coupling Nut" (b).
Hand tighten onto the torch, making sure that the
cone portion of the tip fits correctly into the torch
body.
4. Use a 1" (26mm) wrench to hold the torch body
(a) and a 1 1/8" (29mm) wrench to tighten "Tip
Coupling Nut" (b).
5. Set the torch tip 1/8" above the bottom level of
the igniter.
87
Page
Oxy-Fuel Torch - Torch Tip Cleaning and Changing Procedure Continued

If dross forms on the bottom of the cut.
Causes can be:
The cutting speed is too slow or too fast.

The torch tip is too small or large.
The cutting oxygen is set too low.
88
Page
Painting / Colors
Paint Types
Automotive type paint is used on Peddinghaus "green" and "orange" product.
High temperature paint is used on Peddinghaus "black" product.
Enamel paint is used on Peddinghaus "yellow" product.
Paint colors of new product or spare parts:
Peddinghaus product is painted Peddinghaus Green.
Moving parts that are considered clamps or pinch points are painted in motion color. This color
is presently orange.
Lapeyer (brand) stairs and associated Peddinghaus platforms are painted Lapeyer yellow.
Components that are exposed to high temperature such as parts near torches are painted black
and are indicated as such on assembly drawings.
Manufactured rollers and measuring wheels that have contact surfaces do not have those
surfaces painted.
Hydraulic power units that are purchased complete are painted Peddinghaus Green.
Internal electrical enclosures are orange, external electrical enclosures are green.
Cone drive gear reducer units are painted green.
89
Page
CHAPTER 6 Drawings & Bills

The following assembly drawings were used to assemble your Peddimat machine. They are provided
here to assist you with general maintenance and repair.
90
Page

FDB1500-2500 Instruction Manual

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What are the main components of the machine described in the manual?

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What safety procedures are outlined in the manual?

INSTRUCTION MANUAL for FDB1500 & FDB2500 Plate Processing Systems

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

Options Covered In This Manual:

May 26, 2006, Peddinghaus Corporation YD2313149, Rev 0

Machine Identification Page

Conventions for Notes, Warnings and

General Notes on Safety

Special Sources of Danger

Major electric motors

Hydraulic Power Unit

Misc. Electrical Equipment

Location of Emergency Stop (EStop) Buttons

Notes on Safety for Specific

Machine Description Chapter 2

May 26, 2006, Peddinghaus Corporation YD2313149, Rev 0

List of Recommended Lubricants

Metric Fastener Torques

ASA Steel Tube

Recommended Hydraulic Fluid

Hydraulic Oil Level

Adding Hydraulic Oil

About oil and filters

Hydraulic Power Unit Shutdown

Changing the Hydraulic Oil

Changing Hydraulic Power Unit

About Grease Fittings

Part exit side right

Part exit side center

Part exit side left

Part entry side

Specifications for Standard

Hydraulic power unit

Changing the Hydraulic Power Unit

May 26, 2006, Peddinghaus Corporation YD2313149, Rev 0

Replenishing Coolant Emulsion

Mist Lubricator Filling

Oil delivery drip rate chart

Filter Draining & Replacement

Smoke collector air flow adjustment

Drilling and drill bits

Defects on Drill-Bits and Their Most

Drill Coolant System

About the Signoscript maker

About the Plasma-Torch

Torch tip adjustment

Torch Path Routing

Correct Torch-Travel Direction for

Kerf & Cutter Compensation

Optional Kerf Changes

Plasma torch Summary Notes

Signoscript marker Operation (if

Plasma-Torch operation (if feature

May 26, 2006, Peddinghaus Corporation YD2313149, Rev 0

Oxy-Torch Operation (if feature

The Work Area

Gas Control Panel