PCD 1100/3C ATC
Safety ◦ Installation ◦ Maintenance ◦ Repair ◦ Operation
Original Instructions
Version 1, Revision 3 (February, 2011)
YD2315441
PCD 1100/3C ATC
Our Company...
Peddinghaus Corporation is proud to be serving the steel construction,
plate fabrication, and metal working industries since 1903. Peddinghaus
maintains engineering, customer service, and production facilities in
Bradley, Illinois and Andrews, South Carolina in the
United States, as well as in Gevelsberg, Germany
and Vitoria, Spain. Sales and Service offices are
located throughout the world, specifically in the
UK, Hong Kong, and Mexico.
Peddinghaus is dedicated to engineering expertise
focused on machine productivity. We maintain the
largest staff of field service technicians and
customer support in the industry. Our extensive
parts inventory assures our customers of next-day
parts shipments.
Peddinghaus regularly surveys our customers, and
perhaps they say it best, with a 97% approval rating
of their Peddinghaus purchase within 12 months and
even after 48 months. We are proud to offer our
customers an unmatched quality of service.
To discover the many ways that we can help you make the most of your
Peddinghaus partnership, refer to the Appendix in this manual, visit us at
www.Peddinghaus.com, or call us at 815-937-3800 (USA).
© Peddinghaus Corporation, 2011
All Rights Reserved
© Peddimat Software is a copyright of Peddinghaus Corporation
V1-R3
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 it or any related
equipment. The information in this manual must not be reproduced or distributed for competitive purposes.
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PCD 1100/3C ATC
… and Your Machine
This manual covers the mechanical operation and maintenance of your machine. Some of the
features described may be for optional equipment, which you may or may not have in your
system. All persons supervising, operating, or servicing this machine must read and understand
this manual.
Optional equipment not covered in this manual 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 Peddinghaus Inside Sales.
The PCD 1100/3C ATC High-Speed Drilling Machine by Peddinghaus is designed exclusively for
drilling and marking structural beams, flat stock, channel, rectangular tubing, and angle. The
machine consists of three drilling axes, each having 1 spindle per axis. Each drill spindle has a 5station automatic tool changer which supplies it with the required tools. The drill spindles can be
programmed for any selected drill or drill combination to produce holes or layout marks at the
desired locations. The roller feed drive mechanism allows maximum utilization of material, in that
you may program the machine to process material from lead to trailing edge.
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PCD 1100/3C ATC
PCD 1100/3C ATC
Table of Contents
I: Mechanical Unit
1.0 Safety
Warning Systems ································································································· 1.1
Warning Signs ····································································································· 1.2
Safety Features and Protection Systems ····································································· 1.3
Environmental Safety Features ················································································ 1.4
Closed Circuits ··································································································· 1.5
Interlocking ······································································································· 1.6
Lockout/Tag-out Procedure ···················································································· 1.7
Ear Protection ···································································································· 1.8
Safety Guidelines ································································································ 1.9
Conditions for Safe Use ························································································ 1.10
Personnel Qualifications ······················································································· 1.11
2.0 Machine Components
Machine Construction ···························································································
Axis Definition ····································································································
Layout of Controls ·······························································································
Electrical Cabinet ································································································
2.1
2.2
2.3
2.4
3.0 Operation
Preparation Prior to Start-Up ·················································································· 3.1
Theory of Basic Operation ······················································································ 3.2
Safety for Standard Operational Mode ··················································································· 3.2.1
Safety for Special Operational Modes ···················································································· 3.2.2
Emergency Shutdown Procedure ·············································································· 3.3
4.0 Maintenance & Troubleshooting
Inspection and Maintenance Schedule ········································································ 4.1
Daily Inspection and Maintenance ············································································· 4.2
Around the Machine ·········································································································4.2.1
Mechanical ····················································································································4.2.2
Hydraulic ······················································································································4.2.3
Electrical ······················································································································4.2.4
Pneumatic·····················································································································4.2.5
Weekly Inspection and Maintenance··········································································· 4.3
Mechanical ····················································································································4.3.1
Electrical ······················································································································4.3.2
Computer ·····················································································································4.3.3
Pneumatic·····················································································································4.3.4
Monthly Inspection and Maintenance ·········································································· 4.4
Hydraulic ······················································································································4.4.1
Lubrication ····················································································································4.4.2
Computer ·····················································································································4.4.3
Six Month Inspection and Maintenance ········································································ 4.5
Hydraulic ······················································································································4.5.1
Electric ························································································································4.5.2
Annual Inspection and Maintenance ··········································································· 4.6
V1-R3
Mechanical ····················································································································4.6.1
Electrical ······················································································································4.6.2
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PCD 1100/3C ATC
Troubleshooting ··································································································· 4.7
General System ·············································································································· 4.7.1
Hydraulics ····················································································································· 4.7.2
Pumps ························································································································· 4.7.3
Solenoid Valves ·············································································································· 4.7.4
Filters ·························································································································· 4.7.5
Drill Bits ······················································································································· 4.7.6
Technical Specifications ························································································· 4.8
Screw and Bolt Torque Specifications—Metric ·········································································· 4.8.1
Screw and Bolt Torque Specifications—Standard ······································································· 4.8.2
5.0 Spare Parts
Drill Coolant ······································································································· 5.1
Additional Spare Parts Sources ················································································· 5.2
Ordering Spare Parts ····························································································· 5.3
Returning Spare Parts for Credit ··············································································· 5.4
6.0 Assembly
Handling ············································································································ 6.1
Identification of Components ··················································································· 6.2
Support and Lifting Points ······················································································· 6.3
Machine Alignment and Leveling ··············································································· 6.4
Positioning and Joining of Components ······································································· 6.5
Machine and Component Placement ······················································································ 6.5.1
Check Machine Paint Coverage ···························································································· 6.5.2
Loctite ························································································································· 6.5.3
Dismantling, Disposal, and Reassembly ······································································· 6.6
7.0 Installation
Installation Requirements ······················································································· 7.1
Required Installation Materials and Tools ···································································· 7.2
Installation Procedures ·························································································· 7.3
Electrical Connections ······································································································ 7.3.1
Fusing on the Construction Site and Supply Lines ······································································ 7.3.2
Hydraulic Connections ······································································································ 7.3.3
Pneumatic Connections ····································································································· 7.3.4
Assembly and Installation Inspection ·········································································· 7.4
8.0 Packaging & Storage
Packaging Requirements ························································································ 8.1
Methods of Handling ····························································································· 8.2
Protection from Unwanted Movement ········································································ 8.3
Labeling ············································································································ 8.4
Storage Requirements ··························································································· 8.5
Storage Space ····································································································· 8.6
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PCD 1100/3C ATC
PCD 1100/3C ATC
II: Control Unit
9.0 Basic Machine Operations
Siemens CNC Control General Information ·································································· 9.1
Operating Modes ································································································· 9.2
Jog Mode ·········································································································· 9.3
Jog Mode—Incremental Axis Move ························································································ 9.3.1
Jog Mode—Automatic Tool Changer ······················································································ 9.3.2
MDI Mode ·········································································································· 9.4
Automatic Mode ·································································································· 9.5
Part Program Selection ····································································································· 9.5.1
Load HD » NC ················································································································ 9.5.2
Unload NC » HD ·············································································································· 9.5.3
Start Cycle ··················································································································· 9.5.4
Stop Cycle ···················································································································· 9.5.5
Single Block Execution ····································································································· 9.5.6
View Currently Selected Part Program ·················································································· 9.5.7
Edit Currently Selected Part Program ··················································································· 9.5.8
User Views ········································································································ 9.6
User View #1—”Ped 1” ····································································································· 9.6.1
User View #2—”Ped 2” ····································································································· 9.6.2
10.0 Part Program Management
Copy Part Program ······························································································ 10.1
Rename Part Program ·························································································· 10.2
Delete Part Program or Programs ············································································ 10.3
11.0 Machine Operations
Manual Pushbuttons ···························································································· 11.1
Power On ···················································································································· 11.1.1
E-stop Buttons ·············································································································· 11.1.2
Fault·························································································································· 11.1.3
Tool Mode ··················································································································· 11.1.4
Hyd PU ······················································································································· 11.1.5
Entry VC Disable ············································································································ 11.1.6
Exit VC Disable ············································································································· 11.1.7
Speed OR & Feed OR······································································································· 11.1.8
Reset ························································································································· 11.1.9
Entry Jog Enable and Exit Jog Enable ················································································· 11.1.10
12.0 General Configuration Parameters
V1-R3
Miscellaneous Parameters ····················································································· 12.1
Clamp Parameters ······························································································ 12.2
Tool Changer Parameters ······················································································ 12.3
Spindle Parameters ····························································································· 12.4
Y/Z/W Wear Parameters ······················································································ 12.5
Y/Z/W Tool Parameters ······················································································· 12.6
Y/Z/W Spindle Parameters ···················································································· 12.7
Optional Parameters for MEBA Saw with Epis Control Interface ········································ 12.8
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PCD 1100/3C ATC
13.0 Basic Operations
Calibrate the X-axis ···························································································· 13.1
Determine and Set X-axis Home Position ··································································· 13.2
Determine and Set Y/Z/W-axis Home Positions ··························································· 13.3
Recover from a Program Interruption ······································································· 13.4
All the holes have been drilled ·························································································· 13.4.1
Some of the holes have been drilled, but not all ····································································· 13.4.2
Completing a partially processed part ················································································· 13.4.3
Set Spindle Feed and RPM ····················································································· 13.5
Spindle Feed Axes ········································································································· 13.5.1
Spindle RPM Axes ·········································································································· 13.5.2
Motor Replacement ···························································································· 13.6
Change the Voltage ···························································································· 13.7
Set the Tool Changer Cycle ··················································································· 13.8
Tool Change Procedure ························································································ 13.9
Jog the Measuring Disk························································································ 13.10
14.0 Access Levels
Determining Current Access Level ··········································································· 14.1
Raising the Access Level ······················································································· 14.2
Lowering the Access Level ···················································································· 14.3
Changing Passwords ···························································································· 14.4
15.0 Additional Installed Programs
Peddimat Programming System ·············································································· 15.1
Updating Peddimat ····························································································· 15.2
16.0 Code Listing
17.0 Parameter Screen Program
Parameter Screen ······························································································ 17.1
Category ···················································································································· 17.1.1
Category Selected ········································································································· 17.1.2
Saving Parameters ········································································································· 17.1.3
Loading Parameters ······································································································· 17.1.4
Convert ······················································································································ 17.1.5
NCK Reset ··················································································································· 17.1.6
Refresh Values ············································································································· 17.1.7
Monitor Screen ·································································································· 17.2
Load Monitor File ·········································································································· 17.2.1
Monitor File Format ······································································································· 17.2.2
Command Button Screen ······················································································ 17.3
Load Command Button File ······························································································ 17.3.1
Command Button Example ······························································································· 17.3.2
Appendix I: Peddinghaus Services
Appendix II: Drill Feed & Speed Charts
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PCD 1100/3C ATC
Table of Images
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Safety Features ··································································································· 1-1
Lockout/Tagout Points ·························································································· 1-2
Airborne Noise Emission························································································· 1-3
Laser Location and Path ························································································ 1-4
General Machine Components ················································································· 2-1
Drill Assembly Components ····················································································· 2-2
Axis Definition ···································································································· 2-3
Siemens 840 Di Operator’s Panel ·············································································· 2-4
Control Console ·································································································· 2-5
Electrical Cabinet ································································································ 2-6
Work Hours Counter ····························································································· 4-1
Drill Assembly····································································································· 4-2
Signoscript Cutter Replacement ··············································································· 4-3
Signoscript Depth Adjustment ················································································· 4-4
Hydraulic Fluid Sight Gauge ···················································································· 4-5
Oil Filter Status Indicator ······················································································· 4-6
Drill Coolant Reservoir ·························································································· 4-7
Air Conditioner ··································································································· 4-8
Filter Regulator Unit····························································································· 4-9
Drive Roller Lubrication Points ··············································································· 4-10
Y-axis Drilling Ball Nut Lubrication Point···································································· 4-11
Datum Support Rollers Lubrication Points ·································································· 4-12
Non-Datum Infeed Roller Lubrication Point ································································· 4-13
Non-Datum Support Rollers Lubrication Points ····························································· 4-14
Idler Roller Lubrication Points ················································································ 4-15
Z-axis Drilling Ball Nut Lubrication Point ···································································· 4-16
W-axis Drilling Ball Nut Lubrication Point ··································································· 4-17
Y-axis Position Ball Nut Lubrication Point ··································································· 4-18
Vertical Hold Down Clamp Lubrication Points ······························································ 4-19
Linear Bearing Lubrication Points ············································································ 4-20
Power Unit Components ······················································································· 4-21
Prox Switches ···································································································· 4-22
Prox Switch ······································································································ 4-23
Main Machine Lifting Points ···················································································· 6-1
Shipping Blocks ··································································································· 6-2
Passline Adjustment ····························································································· 6-3
Electric Enclosure ································································································ 7-1
Pneumatic Connection ·························································································· 7-2
Storage Space ····································································································· 8-1
Siemens 804 Di Operator’s Panel ·············································································· 9-1
Machine Control Panel ·························································································· 9-2
Pushbutton Locations ··························································································· 11-1
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PCD 1100/3C ATC
1.0 Safety
1.1 Warning Systems
Warning
All persons involved with the supervising, assembling, installing, operating, or
servicing of your Peddinghaus machine should wear appropriate safety glasses,
safety shoes, hard hats, and protective work gloves.
The control console for your machine notifies the operator of warnings and errors with the system.
Different headings on labels and headings in this manual indicate the severity of the potential hazard.
Note
Notes on operation and safety must be strictly observed and carried out by the operator to
maintain machine performance and protect the work area.
Caution
Refers to operation and maintenance instructions that must be strictly followed
to prevent damage to the machine and the surrounding area.
Warning
Refers to instructions that must be strictly followed to prevent injury or
dismemberment.
Danger
Refers to instructions that must be strictly followed to prevent serious injury or
death.
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Failure to acknowledge and follow the warnings provided in this manual and elsewhere may lead to damage, destruction of
property, injury, or death.
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1.2 Warning Signs
Some of the warning signs on your machine apply to overall safety for anyone near the machine and clearly state what actions
need to be taken to prevent injury. Some of these signs are displayed below.
Location: Operator’s
Console
Hazard: Hot, sharp
chips are ejected during drilling. Anyone
operating the machine
or working in the vicinity must wear safety
glasses with side shields
to prevent eye injury.
Location: Operator’s
Console
Hazard: The machine
produces high levels of
noise during drilling.
Anyone operating the
machine or working in
the vicinity for extended periods must
wear hearing protection.
Location: Operator’s
Console
Hazard:
Unqualified
operators can damage
the machine and are at
greater risk of injury.
Only qualified operators
who have read and understand the manual are
allowed to operate this
machine.
Other signs on your machine are more explicit and apply to a hazard presented by a specific machine part, function, or action that
must be taken by those working on or with the machine.
Location: Electrical Enclosure
Hazard: Machine is remotely controlled and can move
unexpectedly. To avoid serious injury or death, stay
clear of machine during operation.
Location: Horizontal Clamps
Hazard: Clamps may close unexpectedly. Stay clear of
these area during operation to avoid injury.
Location: Under Belt Guards
Hazard: Rotating belts can cause entanglement. Replace guards after service and do not operate with
guards removed.
Location: Inside Electrical Enclosure
Hazard: Risk of shock or improper machine operation
without proper earth connection.
NOTE:
Do not move, remove or deface any
hazard labels applied to the machine.
In addition to hazard warning labels, your
machine is also marked with essential
information such as pressure setting
values, maintenance instructions and
component identifiers.
Setting, adjustment and maintenance data
is presented as white text on a blue field,
often accompanied by the signal word
NOTICE.
Electrical identifiers correspond to the
electrical schematic and hydraulic/
pneumatic identifiers correspond to the
fluid power schematic to make component
identification and replacement easier.
Machine Identification:
Location: X and Y Axes
Hazard: Axes may move unexpectedly. Stay clear of
these areas during operation to avoid injury.
Location: Electrical Enclosure
Hazard: Risk of shock and arc flash due
to high voltage. Never perform hot work
without following NFPA 70E safe work
practices and PPE requirements.
Location: Electrical Enclosure
Hazard: Machine may start or move unexpectedly resulting in severe injury or
death. Always lock and tag out before
servicing or maintaining machine.
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1.3 Safety Features and Protection Systems
Caution
Prior to putting your machine into operation, whether it be at the beginning of
the shift or start-up after break, the location and functionality of the belowdescribed safety devices must be confirmed. Failure to do so can cause serious
injury.
There are several safety features incorporated into your system. These features include:
• Push Button Emergency Stop (E-Stop) Switches—4 on the main body of the machine and 1 on the Control Console
• Perimeter Guard consisting of fencing with interlocked gates, mulit-beam light guard, or a combination of both systems.
• Main Electrical Disconnect—1 on the Electrical Cabinet
• Belt Guards—DO NOT operate machine with these guards removed
E-stop Switches
Main Electrical Disconnect
Belt Guards
E-stop Switches
Figure 1-1: Safety Features
Any time your machine is in E-stop mode or electrical power is off, the hydraulic valves switch to blocked centers to prevent the
cylinders from moving. Axis drives will be shut off to prevent movement of material, which also results in a loss of material
position data.
To reset the E-Stop switches after activating them, give the push buttons a clockwise quarter turn or pull them away
from the machine, depending on the model used.
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Caution
All operators and personnel in the general area of the machine must be made
familiar with the location and operation of all Emergency Stop buttons and other
safety features.
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1.4 Closed Circuits
All E-stops in your system are hooked up in closed circuits. If an E-Stop wire is broken or cut, the machine will automatically shift
into E-Stop mode.
1.5 Interlocking
The main electrical cabinet is designed so that the power to it must be turned off before the cabinet can be opened.
Depending on your general arrangement, your perimeter guarding system also contains interlocked access gates that require a key,
located on the operator’s console, to open. When the key is removed from the operator’s console, hazardous motion within the
perimeter is halted so that the machine system is in a safe status when operator intervention is required. The system cannot be
removed from this mode until the access key is replaced in the operator’s console.
1.6 Lockout/Tag-out Procedure
Follow these steps to release all hazardous energy before performing maintenance on this machine. For more information on
Lockout/Tag-out, see CFR 1910.147, The Control of Hazardous Energy (Lockout/Tagout).
Danger
These steps must be followed before installing, operating, servicing, or
dismantling this machine. Failure to do so can cause serious injury or death.
To lockout/tag-out the machine:
Shut down the machine.
Open the main power disconnect switch on the
power unit’s electrical panel by turning the
handle to the “Off” position.
• Lockout and tag-out the electrical power at the
supply disconnect. This procedure should be
accomplished yourself. Do not rely on others to
perform this operation. Once this is completed,
verify by trying to re-start the machine to
confirm that all electrical power is off.
• Exhaust, vent, lockout, and tag-out pneumatic
and hydraulic pressure that is stored within the
machine. This trapped energy could cause
dangerous, unwanted machine motion. This is
accomplished by locking and tagging out the red
switch on the FRL unit where the air connects to
the machine. Hydraulic pressure is dumped
when the electrical power is disconnected.
• Confirm success of lockout by attempting to restart system at the control.
•
•
Figure 1-2: Lockout/Tag-out Points
Note
Block-center valves are used to prevent drifting of hydraulic axes due to gravity after the
machine has been locked out. However, when performing maintenance tasks on the hydraulic system, you must secure hydraulic axes to prevent unexpected movement when
components are removed.
Warning
Failure to block hydraulic axes when removing components from the hydraulic
system could result in severe injury.
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1.7 Ear Protection
When the machine is idling, it emits noise measuring at approximately 86 decibels (db); however, during material processing
operations, the noise level exceeds 94 db within the typical operator’s zone. It is therefore compulsory for the operator and any
nearby personnel to wear ear protection whenever this machine is in operation.
83.5 db @ 10 feet
94 db @ 10 feet
84 db @ 10 feet
95 db @ 10 feet
88 db @ 10 feet
97 db @ 10 feet
86 db @ 10 feet
97 db @ 10 feet
85.5 db @ 10 feet
96.5 db @ 10 feet
87 db @ 10 feet
96 db @ 10 feet
84 db @ 10 feet
95 db @ 10 feet
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Key
Plain text = idling level
Underlined text = operating level
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86 db @ 10 feet
97 db @ 10 feet
Figure 1-3: Airborne Noise Emission
PCD 1100/3C ATC
1.8 Safety Guidelines
•
•
•
•
•
Only persons adequately trained should operate, assemble, maintain, or perform service on your machine.
Never operate your machine without all safety devices in place and working properly.
Always perform proper shut-down procedure before performing any service to the machine.
Do Not try to process materials not intended to be used on this machine.
Do Not use the machine as a manual drilling device. There are sensors to prevent damage or injury when running that are not
active when the machine is in manual jog mode.
1.9 Conditions for Safe Use
Note
No modifications to your machine are allowed while it is under warranty, unless they are
performed by a Peddinghaus Service Technician.
The operating environment for your machine must have sufficient lighting. Do not operate the machine in areas where the
ambient temperature is less than 40° Fahrenheit (4.4° Celsius) greater than 110° Fahrenheit (43° Celsius). If operating outside of
this temperature range, you will need additional optional equipment sold by Peddinghaus for proper operation.
When operating the machine in cold climates, it must warm up before processing material.
The machine must be protected from outdoor elements such as rain, snow, hail, intense sunlight, strong winds, sand, etc.
All guards and protective systems must be in place and working properly before operating the machine.
Always keep the operating instructions in reach of the machine. In addition to the operating instructions, keep to and apply
general legal rules and other mandatory standards regarding accident prevention and environmental protection.
Staff members engaged in performing work at the machine must read the operating instructions before starting their work,
especially the sections on safety. This applies in particular to personnel that infrequently work on the machine, such as those who
equip or service the machine.
Should mechanical or operational changes leading to dangerous situations occur, 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 install additional components, that may affect the safety of the machine without the permission of the
supplier. This also applies to the installation and adjustment of safety devices and safety valves.
Electrical system work may only be performed by electricians or by persons trained to perform electrical work and under the
supervision of an electrician. Work on the electrical system must be performed in accordance with the applicable rules of
electrical codes.
Hydraulic system work may only be performed by experienced hydraulics personnel.
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 or injury due to the use
of parts, accessories, and/or special equipment that has not been originally supplied by
Peddinghaus Corporation.
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The Y-axis Spindle, the W-axis Drill Unit, and the Z-axis Drill Unit must be fully supported before performing any work on these
cylinders.
The X-axis Zero Switch (located on the W– and Z-axis spindles), and the Safety Light Curtain use a Class 1
Laser product, which complies with 21 CFR 1040.10 and 1040.11, except for deviations pursuant to Laser Notice No. 50, dated 0726-01. Do not disassemble, repair, or modify this product in any way.
Warning
Never stare directly into the sensor lens. Laser light can damage the eye. Avoid
placing reflective surfaces in the path of the beam.
X-axis Zero Switch
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Figure 1-4: Laser Location and Path
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1.10 Personnel Qualifications
Everyone involved with your machine must be properly trained. All personnel must fully read all sections of this manual that are
pertinent to the job they will be performing, and become familiar with the machine before running or working on the machine.
All personnel involved with the machine should have an understanding of general shop practices.
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2.0 Machine Components
2.1 Machine Construction
Y-axis Slide (Concealed)
Left Horizontal Clamp
Z-axis Tool Changer
Z-Tower
W-Tower
Right Horizontal Clamp
Y-axis Spindle
W-axis Tool Changer
W-axis Spindle
Main Electrical Disconnect
Drill Lubrication System
FRL Unit
Hydraulic Power Unit
Air Conditioner
Electrical Cabinet
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Figure 2-1: General Machine Components
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Rotary Union
Spindle Motor
Tool Gripper
Cylinder
Spindle Nose
Spindle
Figure 2-2: Drill Assembly Components
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Chapter 2: Machine
Chapter
Components
1: Safety
PCD 1100/3C ATC
2.2 Axis Definition
AXIS
DESCRIPTION
X
Material Transport
W
W-axis Drill Assembly Vertical Movement
Y
Y-axis Drill Assembly Horizontal Movement
Z
Z-axis Drill Assembly Vertical Movement
Z-Tower
Z-axis Drill Assembly Horizontal Movement
+
Z Feed
-
-
-
W Feed
+
-
-
W Gauge
Z Gauge
+
+
+
Y Gauge
Datum Line
-
Left Horizontal Clamp
X Feed
+
+
Right Horizontal Clamp
-
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Figure 2-3: Axis Definition
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2.3 Layout of Controls
Status LEDs
Power
Temp
Softkeys
Alpha key
group
Numerical
key group
Cursor
key group
Control
key group
USB front
interface
Softkeys
Recall
Machine area
ETC key
Menu Select
Hotkeys
Figure 2-4: Siemens 840 Di Operator’s Panel
Operator’s Panel
Perimeter Guard
Access Key
Space for Customersupplied Programmer’s
Station
E-Stop
Mouse
Control Panel
Figure 2-5: Control Console
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Chapter 2: Machine
Chapter
Components
1: Safety
PCD 1100/3C ATC
2.4 Electrical Cabinet
Your machine contains a Siemens Sitop power supply. It has a three phase input of 320-550 VAC and an output of 24 VDC @ 40
amps.
AC Motor Contactors
and Overloads
Main Disconnect
24VDC Power Supply
Servo Transformer
Primary Breaker
Fuse Blocks
Servo Transformer
Secondary Breaker
Servo / Spindle Drive
Modules
E-stop Relays
Servo Power Contactor
Drive Voltage Sensing
Module
Encoder Feedback
Modules
PLC Input / Output
115V Transformer
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Figure 2-6: Electrical Cabinet
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PCD 1100/3C ATC
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Chapter 2: Machine
Chapter
Components
1: Safety
PCD 1100/3C ATC
3.0 Operation
3.1 Preparation Prior to Start-Up
Prior to the start-up of your machine, make sure each of the following criterion is met:
• Check air oiler level (fill if required).
• Check air filter / separator (empty if required).
• Check power unit oil level.
• Clean area of drill chips. Pay attention to the area around the material clamps, as well as on each spindle.
• Check the cleanliness of all the linear ways, including the Y-, Z-, and W-axes, vertical hold-downs, measuring wheels, and the
Y-, Z-, and W–axis spindles.
• Check the cleanliness of all exposed cylinder rods, including both horizontal clamps, all 4 vertical clamps, and measuring
wheel pull-back.
• Check the sharpness of all drill bits. Sharpen or replace as needed.
• Turn on main power.
Note
The minimum starting temperature of the hydraulic oil is between 54oF and 57oF (12oC and
14oC). The standard operating temperature is approximately 120oF (50oC). When
temperatures are low and during winter, the system must be allowed to warm up before
starting operation. This is required to guarantee proper functioning. Optional hydraulic power
unit oil heaters are available for low temperature operating environments.
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When initiating start-up of your machine:
• All Emergency Stop buttons on the machine must be enabled.
• The Main Power Disconnect located on the electrical cabinet must be “On”.
• Switch on the machine control with the “Power On” push button located on the machine control console. Wait until start-up
screen appears on the video screen. It may take approximately 30-60 seconds for this sequence to occur.
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PCD 1100/3C ATC
3.2 Theory of Basic Operation
The axes on the PCD C all have absolute encoders. These axes do not need to be referenced unless the motors have been
uncoupled from their actuators for maintenance.
To begin, material is loaded onto the infeed conveyor one piece at a time. The placement of the material stock on the infeed
rollers must be put up against the conveyor datum rollers. This insures that the material will feed properly into the machine. We
strongly recommend the leading edge of the material having a trim cut on it before it enters the machine, this will give you a more
accurate finished part. Use the infeed conveyor to position the leading edge of the material just past the machine’s first drive
roller. When manually loading the conveyor, the material stock must not be dropped onto the infeed rollers.
Once the operator loads the material and selects the desired program, press “Cycle Start” to initiate program execution, beginning
with the X-axis-referencing sequence described below:
The (material flow) X-axis reference sequence operates as follows:
The entry side horizontal clamp engages the material, activating the entry Encoder. If the material is already covering the X-REF
switch, the material will move slowly backwards until the X-REF switch is uncovered. At this point, the material will move slowly
forward until the X-REF switch is covered again, and then stop. If the X-REF switch was uncovered to begin with, the material will
move slowly forward until the switch is covered, and then stop. The vertical hold down rollers will come on and off as the program
tells them to.
The machine will next perform the web and drill probing if required. Web probing is determined by the part program and can
either be performed only in the center of the web, or at both edges of the web close to the flanges. The entry side web probe will
extend until it reaches the top of the web; the computer will calculate the center line of the web for the beam, and the control
will determine the location of all the web holes based on this dimension. Drill probing is performed once per drill the first time is
it used if the length is not known by the control. The drill probing starts with the drill extending under reduced force until it
touches the material. (The spindles will not be rotating at this time.) After the drill makes contact with the beam, it will retract to
a safe distance, and then start rotating at the pre-programmed speed. With the Smart Spindle II technology, the spindle will drill
the hole, detect the breakthrough and retract to the same safe distance. For the web drill, information from the web probe/
material clamp is used to reduce time of the drill probe sequence by allowing the spindle to move at rapid speed until it is longest
drill length away from the surface of the material.
Next, the machine will begin drilling. The material will feed to the correct X-dimension, and the drill spindles will drill as the
program directs them to do.
During the drilling cycle, all three drill axes will move independently of each other. All the holes in that X-dimension will be
completed before the machine moves to the next X-dimension.
The tool change process with be performed automatically whenever a tool is required. At the beginning of the tool change process
all spindles will move to their “tool change position”. Any spindle that requires a tool change will then proceed to get the correct
tool, while the spindles that do not require a tool change will remain stationary until the other spindles are finished. Once the
tool change process is complete, the drilling cycles will continue.
When the trailing edge of the material reaches the saw (provided you have one in tandem with the drill) the saw will cut the part
to length. The machine will then move to the next X-dimension locate and finish drilling holes in the part. When the trailing edge
of the material reaches the first (entry) Encoder, the material will stop momentarily. The first (entry) Encoder will open,
activating the second Encoder (on the exit side). The (entry side) vertical hold down will also open. After a short delay, further
processing will continue.
After all program instructions have been executed, the Z-tower clamp and (exit side) hold-down will open. Any material left in the
machine should now be removed.
When shutting down this machine:
1. Press the “Exit” Soft Key button on the Control Console. Wait for the “It is now safe to turn off your computer—Restart”
message to display.
2. Press the “Power Off” button to shut off the control and the power to the machine.
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Chapter
Chapter
3: Operation
1: Safety
PCD 1100/3C ATC
3.2.1 Safety for Standard Operational Mode
Operate the machine only if all protective and safety installations (e.g. removable safety devices, emergency devices) have been
installed and are functioning.
Check the machine at least once every shift for externally visible damage and irregularities. Any changes (including changes in
operation) must be immediately reported to the person/department responsible. 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.
3.2.2 Safety for Special Operational Modes
Always follow the recommended schedule and instructions for maintenance operations, inspection procedures, adjustments, and
part replacement. These operations must be performed only by expert personnel.
Observe the machine activation and deactivation procedures described in the operating instructions as well as the notes on
maintenance—
• For all operations, production adaptation, re-equipping, or adjustment of the machine and its safety installations.
• For all inspection, maintenance, and repair procedures.
Always safeguard the area of maintenance.
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 completely re-tighten screw connections that were loosened for maintenance and repair work. Refer to specific assembly
drawings for torques.
If safety equipment (guards, covers, E-Stops, etc.) need to be removed for maintenance or repair procedures, they must be
remounted and inspected immediately after the work has been completed.
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The operating and process materials, as well as replacement parts, must be disposed of in a way that is not harmful to the
environment.
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PCD 1100/3C ATC
3.3 Emergency Shutdown Procedures
In case of emergency, first trigger one of the Emergency Stop (E-Stop) switches.
Then, depending on the severity of the emergency, do all of the following that apply:
• Turn off power to the entire machine.
• Disconnect air supply to machine.
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Chapter
Chapter
3: Operation
1: Safety
PCD 1100/3C ATC
4.0 Maintenance & Troubleshooting
4.1 Inspection and Maintenance Schedule
Symbol “◊” indicates the inspection / maintenance interval.
Note
Faithfully keep a maintenance log to ensure that all the machine’s needs are met. Consult all
other manuals received with this machine to ensure that every part of your machine is fully
maintained.
Inspection/ Maintenance Intervals
Items
Daily
Weekly
(50 h)
Monthly
(200 h)
Every 6 months
(1250 h)
Every year
(2500 h)
Refer to
Section
Around the Machine
Dispose of corrosion, scale, and drill
chips
◊
4.2.1
Check for oil and grease spills
◊
4.2.1
Mechanical
◊
Inspect hoses for leaks
Check for loose fasteners and
damaged equipment
4.3.1
◊
4.2.2
◊
Inspect the proximity (prox) switches
(when replaced /
adjusted)
4.6.1
Inspect tooling for chips and dull
edges
◊
4.2.2
Check Signoscript cutter sharpness
and depth
◊
4.2.2
Hydraulic
◊
Inspect idle system pressure
Check hydraulic fluid level
◊
(first time)
◊
Replace low pressure filter element
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4.2.3
◊
Change hydraulic oil
Check oil filter status indicators
4.4.1
◊
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◊
4.5.1
4.5.1
4.2.3
PCD 1100/3C ATC
Daily
Weekly
(50 h)
Monthly
(200 h)
Every 6 months
(1250 h)
Every year
(2500 h)
Refer to
Section
Lubrication
◊
Grease all lubrication points
4.4.2
Electrical
◊
Check all terminal connections
Check Emergency Stop (E-stop)
buttons for correct operation
◊
4.6.2
4.2.4
Check the functions of the operating
elements
◊
4.6.2
Check and adjust the control and
auxiliary voltages
◊
4.6.2
Check the electrical cabinet air
conditioner
◊
4.3.2
Check electrical lines for mechanical
damage
◊
4.6.2
Check the shaft encoder attachment
and coupling
◊
4.6.2
Computer
Create system backup of computer
hard drive
◊
4.3.3
◊
Clean computer screen & keyboard
4.4.3
Pneumatic
Check the mist lubricator
◊
4.3.4
Check pneumatic air filter
◊
4.3.4
Check drill coolant reservoir
Check tubing for damage
◊
4.2.5
◊
4.3.4
Warning
Before performing any maintenance, repair, or adjustments on this machine,
shut down the machine and follow proper lockout/tag-out procedures. Secure
any parts that are usually held in place by the machine’s hydraulic or pneumatic
power.
Warning
Remove all tools, material and debris and replace any guards or other safety
devices removed during maintenance before resuming operation of the
machine. Failure to replace guards could lead to serious injury.
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Chapter 4: Maintenance &Chapter
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PCD 1100/3C ATC
To check the work hours counter:
Locate the work hours counter in the lower
right hand side of the electrical panel.
• Use the work hours counter to determine how
many production hours have passed and when
maintenance and inspection practices should
take place.
•
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Figure 4-1: Work Hours Counter
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PCD 1100/3C ATC
4.2 Daily Inspection and Maintenance
4.2.1 Around the Machine
Dispose of Corrosion, Scale, and Drill Chips
Place metal scraps in a pre-designated container and dispose of in an environmentally friendly manner.
Warning
Do not touch metal scraps with bare hands, as this could cause injury.
Check for Oil and Grease Spills
Visually assess the machine, hydraulic power unit, hoses, and the machine’s immediate area for any signs of oil leakage or spilling.
If an oil leak or spill is found, it should be cleaned immediately to prevent work surfaces from becoming hazardous. Repair the
source of the spill or leak immediately.
4.2.2 Mechanical
Check for Loose Fasteners and Damaged Equipment
Any loose or damaged equipment must be repaired or replaced before operating the machine.
Inspect Tooling for Chips or Dull Edges
Make sure that the tips of the drills are sharp and not damaged or broken. If any tooling is dull or damaged, replace it before
operating the machine. The machine’s software has a provision for changing the drill bits on the machine. Refer to Chapter 13 for
the location of the “Tool Change Button” in the program menus.
Drill Spindle
To change the drill body or inserts:
• Remove the tooling from the tool changer.
• Loosen the clamping setscrew in the tool
holder.
• Remove the drill body from the tool holder.
• Using the hex or torx wrench supplied with the
drill body, loosen the locking screw and remove
the drill insert.
• Install the new insert and tighten the locking
screw.
• Install the drill body with new insert back into
the tool holder.
• Tighten the clamping setscrew in the tool
holder.
• Return the tooling to the tool changer.
Tool Holder
Retention Knob
CAT-40 Tool
Holder
Clamping
Setscrew
Drill Body
Drill Insert
Locking Screw
Figure 4-2: Drill Assembly
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Chapter 4: Maintenance &Chapter
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PCD 1100/3C ATC
Check Signoscript Cutter Sharpness and Depth
Make sure that the edges of the cutter are sharp and are not chipped or worn. The Signoscript is an optional marking tool available
with the machine that creates characters and layout marks on the work piece. It uses a carbide cutter, which is pushed into the
material. The distance that the cutter sticks out beyond the material reference foot determines the depth and width of the cut.
Guard Mounting Threads
Collet
Collet Nut
Tool Holder
Cutter
Guard Set Screw
Guard
Figure 4-3: Signoscript Cutter Replacement
To replace the cutter:
Loosen the guard set screw and rotate the guard counterclockwise to remove it from the assembly.
Using the 17mm and 20mm wrenches provided with the assembly, loosen the collet nut and pull the cutter and the tool holder
out of the collet.
• Remove the cutter from the tool holder with the cutter wrench and Allen wrench provided with the assembly, and replace
with a new cutter.
• Slide the tool holder and cutter all the way into the collet (to ensure maximum rigidity), and tighten the collet nut to secure
the parts in place.
• Rotate the guard clockwise to completely reassemble the assembly, and tighten the guard set screw.
•
•
The distance that the cutter extends beyond the front face of the guard
determines the depth and width of the cut.
To adjust the Signoscript cutting depth:
• Loosen the guard set screw.
• Rotate the guard on its mounting threads to
raise or lower the cutter to obtain the desired
depth and width of cut.
• Retighten the guard set screw.
Cutting Depth
Guard Front
Face
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Figure 4-4: Signoscript Depth Adjustment
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PCD 1100/3C ATC
4.2.3 Hydraulic
Check the Level of Hydraulic Fluid
The level of hydraulic fluid in the power unit must be checked daily to ensure that the unit functions properly.
To check the hydraulic fluid level:
Look at the sight gauge, located on the side of
the power unit.
• The fluid level should never be higher than
halfway up the gauge.
• The fluid must be replenished when the fluid
level has dropped below the minimum
observable level of the sight gauge.
• Note: The hydraulic fluid will flood the area
surrounding the thermometer. Use the
thermometer to monitor the temperature of the
fluid.
• Note: The maximum capacity of this tank is 20
gallons (75.7 liters).
•
Figure 4-5: Hydraulic Fluid Sight Gauge
To replenish the hydraulic oil:
• Switch off the system at the main power switch at the main electrical cabinet exterior using Lockout/Tag-out procedures.
• Screw off the tank breather cap.
• Fill the tank with hydraulic oil using a funnel until the fluid level reaches the midway level in the sight glass.
• Screw the tank breather cap back on.
Consult the Power Unit manual for more information.
Check the Oil Filter Status Indicator
The indicator shows the productiveness of the filter, and when it should be replaced.
To check the oil filter status indicator:
Look at the indicator, mounted on the side of
the filter housing.
• Make sure the machine is running. The visual
indicator device is fully functional only when
the power unit is running.
• Take whatever action is necessary according to
the status of the red button indicator. Consult
the Power Unit manual for more information.
•
Filter Status
Indicator
Figure 4-6: Oil Filter Status Indicator
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Chapter 4: Maintenance &Chapter
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PCD 1100/3C ATC
4.2.4 Electrical
Check Emergency Stop (E-stop) Buttons for Correct Operation
Before beginning machine operation, ensure that each E-stop button and mechanism functions as it should.
• See section 1.3 of this manual for more details.
4.2.5 Pneumatic
Check the Drill Coolant Reservoir
Visually inspect the Coolant Tank, located on the side of the machine, to ensure that it is sufficiently filled with fluid.
This machine is equipped with an air cooling system for the drill bits, which adds oil to the cooling air. Peddinghaus recommends
the use of PeddiCool cutting oil for this system.
Reservoir Lid Cap
Drill Coolant Reservoir
To fill the drill coolant reservoir:
Open the cap on the drill coolant reservoir lid.
Using a clean funnel, fill the drill coolant
reservoir with PeddiCool cutting oil until the
reservoir is almost full.
• Remove the funnel, and close the drill coolant
reservoir lid cap.
• Reservoir capacity is 0.5 gallons (1.3 liters).
•
•
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Figure 4-7: Drill Coolant Reservoir
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PCD 1100/3C ATC
4.3 Weekly Inspection and Maintenance
4.3.1 Mechanical
Inspect Hoses for Leaks
Check all hoses at least once a week and prior to running each new job, especially if the machine goes through heavy-duty and
continuous production cycle. Look for cracks, splits, wear, and abrasion
In particular, inspect all of the high-pressure hoses and the hose-to-hose joints for signs of cracking, wear, fraying, or splitting. If
any hose shows any signs of this kind of damage, replace the hose assembly immediately.
For replacement hoses and hose assemblies, contact the Peddinghaus Service Department.
4.3.2 Electrical
Check the Electrical Cabinet Air Conditioner
The air conditioner on the side of the electrical cabinet keeps the internal air of the cabinet from becoming so warm as to damage
the delicate components inside. The air conditioner must be kept clean and unclogged if it is to function properly.
To clean the air conditioner:
Remove the screws holding the faceplate onto
the unit.
• Clean the components of the air conditioner
with a soft brush or pressurized air.
• Replace the faceplate and the screws.
• See the air conditioner manual shipped with this
machine for more maintenance details.
•
Faceplate
Screws
Figure 4-8: Air Conditioner
4.3.3 Computer
Create a System Backup of the Computer Hard Drive
This ensures that you will not lose a significant amount of information should outside conditions cause the computer to fail or lose
data.
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Chapter 4: Maintenance &Chapter
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PCD 1100/3C ATC
4.3.4 Pneumatic
Check for Tubing Damage
Check the pneumatic system for visible leaks, damage, and sharp bends. Any damaged tubing should be removed and replaced.
Note
Collect and dispose of the contaminated liquid in an environmentally safe manner.
Regulator Adjustment
Valve
Shut-off Valve
Locking Tab
1/2” NPT Connection
Port
Filter
Silencer
Push to
drain
Figure 4-9: Filter Regulator Unit
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Check the Filter and Regulator
• Shut off the air supply and depressurize the unit by turning the red shut-off valve to Exhaust (EXH).
• Pull the locking tab and give the polycarbonate bowl a quarter turn clockwise to remove the bowl.
• Unscrew the lower baffle and remove the filter element and gasket.
• Clean all internal parts, bowl, and filter element using mild soap and water only. Do not use cleaning agents such as acetone,
benzene, carbon tetrachloride, gasoline, toluene, etc.
• Install the element and gaskets.
• Attach the lower baffle and tighten firmly.
• Lubricate the bowl seal with only mineral-based oils or grease, and replace it.
• Replace the bowl.
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PCD 1100/3C ATC
4.4 Monthly Inspection and Maintenance
4.4.1 Hydraulic
Inspect Idle System Pressure
Referencing the gauge on the power unit, make sure that the idle system pressure is at the correct level (1750 psi). Any
adjustment in pressure settings can only be made by a Peddinghaus Service Technician.
4.4.2 Lubrication
Grease all Lubrication Points
Take particular notice of the lubrication schedule, the lubrication intervals, and the list of recommended lubricants. Before initial
startup of the machine, all lubrication points must be supplied with sufficient lubricant.
Lubricant
Lithium Grease (Mobil HP)
Lubrication Intervals
Every 200 hours with grease gun at the entry and
exit sides of the system
Lubrication Points
Figure 4-10: Drive Roller Lubrication Points
Lubrication Point
(Shown with Belt Guard Removed; Replace All Guards
Removed for Maintenance before Operating Machine
Figure 4-11: Y-axis Drilling Ball Nut Lubrication Point
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Chapter 4: Maintenance &Chapter
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PCD 1100/3C ATC
Figure 4-12: Datum Support Rollers Lubrication Points
Figure 4-13: Non-Datum Infeed Roller Lubrication Point
Note: These lubrication points
can be found on the entry and
exit sides of the machine
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Figure 4-14: Non-Datum Support Rollers Lubrication Points
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PCD 1100/3C ATC
Note: These lubrication points
can be found on the entry and
exit sides of the machine
Figure 4-15: Idler Roller Lubrication Points
Figure 4-16: Z-axis Drilling Ball Nut Lubrication Point
Note: These lubrication points in Figures 4-16 and 4-17 can
only be accessed by removing the orange belt guards. Replace
all guards removed for maintenance before operating machine
Figure 4-17: W-axis Drilling Ball Nut Lubrication Point
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Chapter 4: Maintenance &Chapter
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PCD 1100/3C ATC
Note: These lubrication points may only be accessed by
removing the orange belt guards. Replace all guards
removed for maintenance before operating machine
Figure 4-18: Y-axis Position Ball Nut Lubrication Point
Note: These lubrication points can be
found on the entry and exit sides of the
machine (datum and non-datum)
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Figure 4-19: Vertical Hold Down Clamp Lubrication Points
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PCD 1100/3C ATC
Figure 4-20: Linear Bearing Lubrication Points
4.4.3 Computer
Clean Computer Screen and Keyboard
Use a soft cloth and glass cleaner to clean both the computer screen and the keyboard. Clean these as often as is required based
on usage and operation conditions.
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PCD 1100/3C ATC
4.5 Six Month Inspection and Maintenance
4.5.1 Hydraulic
Change the Hydraulic Oil
The first hydraulic oil change should take place after six months of use; after that, the oil can be changed annually.
• For normal workplace conditions and temperature, use Mobil DTE 24 or equivalent.
• For extended workplace temperatures below 50° F (10° C), use Mobil DTE 13M or equivalent.
Alternative Hydraulic Oil Specifications:
• Premium oil with a viscosity range between 150-250 SSU (30-50 CST) at 100° F (38° C). Normal operating viscosity range
between 80-1000 SSU (17-180 CST).
• Maximum start-up viscosity of 4000 SSU (1000 CST).
• The oil should have maximum anti-wear properties, including rust and oxidation treatment.
• Note: The maximum capacity of the power unit reservoir is 20 gallons (75.7 liters).
Refer to the Power Unit Maintenance Manual for information on changing oil and inspecting the reservoir.
Main System Pressure Gauge
Motor
Return Filter
Pump (located inside tank)
Sight Glass
Tank Heater Port
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Figure 4-21: Power Unit Components
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PCD 1100/3C ATC
4.5.2 Electric
Check the Shaft Encoder Attachment and Couplings
Have a trained electrician check the encoder fixtures and couplings, and test the security of the connections.
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4.6 Annual Inspection and Maintenance
4.6.1 Mechanical
Inspect the Proximity (Prox) Switches
• The Control Panel Computer will indicate if any of the prox switches need to be adjusted.
• If the Prox Switches are dirty, wipe them with a damp cloth to remove any metallic residue that may prevent the switches
from working properly.
4
2
5
3
6
1
7
13
12
8
10
9
11
1. Z-axis feed (+)
5. Y-axis feed (-)
9. W-axis gauge (-)
12. Z-axis gauge (-)
2. Y-Z-axis crash
6. W-axis feed (-)
10. Measuring Wheel
13. Z-axis gauge (+)
3. Y-axis gauge (-)
4. Y-axis feed (+)
7. W-axis feed (+)
8. W-axis gauge (+)
11. Right horizontal clamp crash
Figure 4-22: Prox Switches
Note: Figure 4-22 is shown with belt guards
removed. Replace all guards removed for
maintenance prior to operating machine.
•
•
Check all prox switches to make sure that
the switch is secure and the lock nut is in
place. The prox switch gap has been set at
the factory; if all switches are secure and
nuts tightly locked into place, the gap does
not need to be adjusted.
Any adjustments must be carried out by
Peddinghaus Service Technicians only.
Lock Nut
Flat Surface
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Figure 4-23: Prox Switch
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PCD 1100/3C ATC
4.6.2 Electrical
For the following electrical maintenance, employ a Peddinghaus Service Technician or professional electrical technician.
• Check all terminal locations
• Check the functions of the operating elements
• Check and adjust the control and auxiliary voltages
Use an AC voltmeter to measure the secondary voltage of the control transformer, and a DC voltmeter to measure the 24volt DC secondary power supply at the corresponding terminal strip.
• Check the electrical lines for mechanical damage
Inspect all electrical lines on the machine to ensure that they have not been cut or otherwise damaged by
machine and shop conditions. Should any wiring need to be repaired or replaced, the work should be performed by a
trained professional.
• Check the shaft encoder attachment and coupling
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Chapter 4: Maintenance &Chapter
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PCD 1100/3C ATC
4.7 Troubleshooting
4.7.1 General System
Problem
Excessive Heat
Possible Causes
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Refer to
Power unit is operating in direct sunlight, high ambient
temperatures, or poorly circulated air.
Cool/ventilate the machine’s
surroundings
The hydraulic fluid has a lower viscosity than required
Replace hydraulic fluid
Excessive internal leakage of hydraulic component
Replace/repair leaking component
-
Cavitation and slippage in a pump
Contact Service Department
-
Cavitation or air in the hydraulic fluid
Contact Service Department
-
Contaminated hydraulic fluid or filter
Excessive Noise
Corrective Action
Power Unit
Manual,
4.5.1
The hydraulic fluid has a higher viscosity than required
Replace hydraulic fluid and/or
filter
Power Unit
Manual,
4.5.1
The reservoir level is low
Replenish hydraulic fluid
Power Unit
Manual,
4.5.1
A coupling is worn or damaged
Replace coupling
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-
PCD 1100/3C ATC
4.7.2 Hydraulics
Problem
Dirty Oil
Foaming Oil
Moisture in the Oil
Possible Causes
Corrective Action
Refer to
Components were not cleaned after servicing
Replace oil and clean components
Power Unit
Manual,
4.5.1
Air breather has been left off
Replace oil and install the breather
properly
Power Unit
Manual,
4.5.1
Hydraulic lines were not covered during service
Contact Service Department
Filter needs to be replaced
Replace the oil filter
Power Unit
Manual,
4.5.1
Oil level is too low
Replenish hydraulic oil
Power Unit
Manual,
4.5.1
Oil is contaminated with an incompatible foreign
material.
Replace oil
Power Unit
Manual,
4.5.1
Suction leaks in the pump are aerating the oil
Contact Service Department
Lack of anti-foaming additives in the oil
Replace oil
Soluble oil solutions have splashed into an unsealed pump
or open fill pipes
Contact Service Department
-
Extreme fluctuation of ambient temperatures
Regulate machine’s ambient
temperatures
-
Excessive sump sediment in the system
Replace hydraulic oil
-
Power Unit
Manual,
4.5.1
Power Unit
Manual,
4.5.1
Ten Rules of Hydraulic System Maintenance
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Plug all leaks.
Look at the fluid daily to ensure that it is free from contaminants, water, and foam.
Listen for unusual noises in the system.
Keep fluid at a moderate temperature—preferably between 90° and 120° F (32° and 49° C).
Keep the reservoir full of fluid.
Clean or change filters, strainers, and magnets when required.
Use only fluids that meet pump specifications.
Add only clean, new oil using a strainer or filter.
Use only clean, well-marked containers for adding oil.
Have your fluid tested periodically to see if it needs to be filtered or changed.
38
4
V1-R3
Chapter 4: Maintenance &Chapter
Troubleshooting
1: Safety
PCD 1100/3C ATC
4.7.3 Pumps
Problem
Possible Causes
Vacuum leaks in the suction line or in the pump shaftseal
Corrective Action
Refer to
Contact Service Department
-
Fluid is not compatible with the system
Contact Service Department
-
Fluid level is too low
Fill to correct level
Worn or faulty bearings
Contact Service Department
Reversed pump rotation
Reverse electrical phase
Plugged or restricted suction line or strainer
Contact Service Department
Plugged reservoir filter breather
Replace filter breather
Oil viscosity is too high or operating temperature is too
low
Contact Service Department
-
Loose or worn pump parts
Contact Service Department
-
Air bubbles in the intake oil
Contact Service Department
-
Pump housing bolts or mounting bolts loose or not
properly torqued
Contact Service Department
-
Low fluid level in the reservoir
Fill to correct level
Oil intake pipe’s suction strainer is plugged
Contact Service Department
-
Oil viscosity is too high or operating temperature is too
low
Contact Service Department
-
Broken pump shaft or parts
Contact Service Department
-
Dirt or debris in pump
Contact Service Department
-
Reversed pump rotation
Reverse electrical phase
Shaft seal is worn
Replace pump
Pump housing bolts loose or improperly torqued
Contact Service Department
-
Abrasive dirt or debris in the hydraulic oil
Contact Service Department
-
Oil viscosity is too low
Contact Service Department
-
Pump is misaligned with the motor shaft
Contact Service Department
-
Air is being drawn through the inlet of the pump
Contact Service Department
-
Seizure due to lack of oil
Contact Service Department
-
Excessive torquing of housing bolts
Contact Service Department
-
Solid matter being drawn in from the reservoir and
getting wedged in the pump
Contact Service Department
-
Pumps are not aligned with the drive mechanism
Pumps Making Excessive Noise
Pump Fails to Deliver Fluid
Oil Leakage Around Pump
Excessive Pump Wear
V1-R3
Broken Pump Parts Inside the
Housing
3
39
Visit us at www.Peddinghaus.com
Power Unit
Manual,
4.5.1
-
Power Unit
Manual
Power Unit
Manual,
4.5.1
Power Unit
Manual
PCD 1100/3C ATC
4.7.4 Solenoid Valves
Problem
Possible Causes
Corrective Action
Refer to
Burnt-out coil caused by low voltage
Solenoid Failure During Operation
Solenoid Valve Fails of Operate
Both solenoids of a double solenoid valve receiving signals
Contact Service Department
simultaneously
-
Iron dust or metallic chips collected within the magnetic
field of the solenoid
Contact Service Department
-
Mechanical damage to the leads caused by a short circuit,
Contact Service Department
open connections, etc
-
Mechanical damage to the coils caused by a short circuit,
open connections, etc
Contact Service Department
-
Tight spool of other mechanical parts of the valve being
actuated
Contact Service Department
-
Lack of electric flow to the solenoid or operating device
Contact Service Department
-
Foreign matter is jammed in the main spool
Replace valve
Fluid media temperature exceeding the recommended
range
Contact Service Department
-
Foreign material in the oil causing gumming deposits
Contact Service Department
-
The system lacks adequate fluid to actuate the load
Fill tank to correct level
-
4.7.5 Filters
Filter Maintenance
• Establish a filter maintenance schedule and follow it diligently.
• Inspect filter elements that have been removed from the system for signs of failure that may indicate that the service
intervals should be shortened and of impending system problems. Periodic inspection of the filter element in a new machine is
desirable, to determine the proper replacement interval.
• DO NOT return any fluid to the system that has leaked out.
• Always keep the supply of fresh fluid covered tightly.
• Use clean containers, hoses, and funnels when filling the reservoir.
• Use common sense precautions to prevent the introduction of dirt into components that have been temporarily removed from
the circuit.
• Make sure that all cleanout holes, breather caps, and breather cap filters on the reservoir are properly fastened.
• Make sure that the fluid used in the system is a type recommended by Peddinghaus Corporation.
• Before changing from one type of fluid to another (i.e. from petroleum-based oil to a fire-resistant fluid), contact Peddinghaus
Corporation’s Service Department. Hydraulic oil cannot be replaced with fire-resistant fluid on most standard Peddinghaus
power units.
40
4
V1-R3
Chapter 4: Maintenance &Chapter
Troubleshooting
1: Safety
PCD 1100/3C ATC
4.7.6 Drill Bits
Problem
Heavy wear on the cutting corners
Splintering on the chisel edge
Built-up edge
Possible Causes
Insufficient coolant
Check cooling lubricant supply. Decrease coolant
pulse interval. Verify air pressure consistency
during drilling.
Cutting speed too fast
Reduce cutting speed.
Feed speed too slow
Increase feed speed.
Screws on the tool holder not secure
Check clamping accuracy. Check the tension of
the tool holder screws.
Feed speed too slow
Increase feed speed.
Insufficient coolant
Check cooling lubricant supply. Decrease coolant
pulse interval. Verify air pressure consistency
during drilling.
Cutting speed too slow
Increase cutting speed 20-30%.
Screws on the tool holder not secure
Check clamping accuracy. Check the tension of
the tool holder screws.
Cutting conditions caused by built-up edge
Check cutting values, and possibly increase
cutting speed. Examine regularly for built-up
edges.
Insufficient/inconsistent coolant supply
Check cooling lubricant supply. Decrease coolant
pulse interval. Verify air pressure consistency
during drilling.
Excessive workpiece movement
Stabilize workpiece chucking and check the
stability of the machine tool.
Insufficient coolant
Check cooling lubricant supply. Decrease coolant
pulse interval. Verify air pressure consistency
during drilling.
Incorrect drill selection
Check drill type, drilling depth, cooling system,
and workpiece material.
Incorrect cutting conditions
Check cutting parameters at exit. Reduce feed
15-20% prior to breakout.
Incorrect cutting conditions
Check cutting values, increase cutting speed, or
reduce feed.
Screws on the tool holder not secure
Check clamping accuracy and torque
transmission. Check the tension of the tool
holder screws.
Splintering on the cutting edges
Thermal checking/comb cracking
Splintering on the lands
Hole too big
Incorrect drill selection
Insufficient coolant
Hole too small
V1-R3
Hole not cylindrical
3
41
Corrective Action
Check drill diameter. Note that drills are ground
to a positive tolerance. Check concentric
running.
Check cooling lubricant supply. Decrease coolant
pulse interval. Verify air pressure consistency
during drilling.
Incorrect cutting conditions
Reduce cutting speed; increase feed
Incorrect drill selection
Check cutting edge diameter
Screws on the tool holder not secure
Check clamping accuracy and torque
transmission. Check the tension of the tool
holder screws.
Workpiece movement
Stabilize workpiece.
Incorrect drill selection
Check drill type and depth.
Incorrect cutting conditions
Reduce feed at entry.
Visit us at www.Peddinghaus.com
Refer to
PCD 1100/3C ATC
42
4
V1-R3
Chapter 4: Maintenance &Chapter
Troubleshooting
1: Safety
PCD 1100/3C ATC
4.8 Technical Specifications
Type
Units of Measurement
PCD 1100/3C ATC
Material Processing Specifications
Maximum Machining Width
Inches (mm)
44 (1100)
Minimum Machining Width
Inches (mm)
2 (50)
Maximum Machining Height
Inches (mm)
18 (460)
Minimum Bar Stock Thickness
Inches (mm)
3/4 (20)
Minimum Length Piece Part
Inches (mm)
64.25 (1632)
Maximum Work Piece Weight
Pounds (kg)
300/foot, max weight of 18,000 (447/meter,
max weight of 8165)
Web and Flange Assembly Specifications
Maximum Horizontal Travel Speed
Ft/min (m/min)
130 (39.6)
Maximum Web Travel Speed
Ft/min (m/min)
40 (12.2)
Maximum Flange Travel Speed
Ft/min (m/min)
40 (12.2)
Operating Power Requirements
Standard Voltage, Phase, Hertz
—
Power Consumption
kVA
480, 3, 60 (380/415, 3, 50)
63
Hydraulic Power Unit Specifications
Motor Power
Hp (kW)
3 (2.2)
Hydraulic Pressure
psi (bar)
1750 (121)
Air Usage Specifications
Air Consumption
cu. ft/min (cu. m/hr)
60 (1097)
Air Pressure
psi (bar)
90 (6)
Max Air Pressure
psi (bar)
125 (8.6)
Maintenance Unit Connection Size
—
1/2”
Material Clamping Pressure
psi (bar)
1750 (120.7)
Available Clamping Force (Horizontal)
Min-max pounds
(Min-max kg)
1963-8590 (890-3896)
Available Clamping Force (Vertical)
Min-max pounds
(Min-max kg)
707-3092 (320-1402)
V1-R3
Maximum Horizontal & Vertical Clamping
Pressure (each separately controlled)
3
43
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PCD 1100/3C ATC
Type
Units of Measurement
PCD 1100/3C ATC
Drill Spindle Specifications
Number of Drill Spindles
—
3
Drill Spindles per Axis
—
1
Power Per Spindle
Hp (kW)
25 (18.7)
Drill Spindle Rapid Advance Speed
Feet/min (m/min)
40 (12.2)
Variable Feeds (individually for every spindle
controlled by CNC)
Inches/min (mm/min)
0-40 (0-1016)
Speeds Controlled by CNC
Min-max RPM
0-2250
Minimum—Maximum Tooling Length
Min-max inches (mm)
5.43-15.24 (138-387)
Drill Diameter
Min-max inches (mm)
3/8-1 9/16 HSS, 3/8-1 1/4 Carbide (8-40
HSS, 8-32 Carbide)
Maximum Drill Gauge Length
(spindle face to drill point)
Inches (mm)
15.25 (387.5)
Minimum Drill Gauge Length
(spindle face to drill point)
Inches (mm)
5.43 (138)
Standard Hydraulic Oil Specifications
Minimum Temperature
°F (°C)
54 (12)
Standard Operating Temperature
°F (°C)
100-120 (38-49)
Maximum Temperature
°F (°C)
130 (55)
Standard Operating Viscosity Range
SSU (CST)
80-1000 (17-180)
Viscosity Range @ 100°F (38°C)
SSU (CST)
150-250 (30-50)
Maximum Start-Up Viscosity
SSU (CST)
4000 (1000)
Equipment and Module Weights
PCD 1100/3C ATC Main Machine
(includes Remote Control Console)
Lbs (kg)
16,000 (7257)
Transformer Weight
Lbs (kg)
615 (278.96)
Control Console Weight
Lbs (kg)
470 (213.19)
Control Information
Control Type
—-
Siemens CNC
Physical Machine Size Data
Machine Dimensions
(Height x Width x Length)
Approx. inches
(Approx. mm)
100 x 92.5 x 200
(2360 x 2346 x 5071)
44
4
V1-R3
Chapter 4: Maintenance &Chapter
Troubleshooting
1: Safety
PCD 1100/3C ATC
4.8.1 Screw and Bolt Torque Specifications—Metric
Socket Head Cap Screw, Class 12.9
Torque Induced Screw
Stress
Hex Head Cap Screw, Class 10.9
General Usage
Special Usage (Use
when specified by
Engineering
General Usage
w/ High Strength
Washers (Use when
specified by
Engineering
32,000 PSI (220 MPa)
100,000 PSI (690 MPa)
20,000 PSI (138 MPa)
90,000 PSI (620 MPa)
Dry
Lubed or
Loctited
Dry
Lubed or
Loctited
Dry
Lubed or
Loctited
Dry
Pitch
Tensile
Area
(mm2)
Lubed or
Loctited
M4
0.7
8.8
13 in-lb
147 N-cm
10 in-lb
113 N-cm
N/A
N/A
8 in-lb
90 N-cm
6 in-lb
68 N-cm
N/A
N/A
M5
0.8
14.2
27 in-lb
305 N-cm
21 in-lb
237 N-cm
N/A
N/A
17 in-lb
192 N-cm
13 in-lb
147 N-cm
N/A
N/A
M6
1
20.1
46 in-lb
5.2 N-m
35 in-lb
4.0 N-m
N/A
N/A
29 in-lb
3.3 N-m
22 in-lb
2.5 N-m
N/A
N/A
M8
1.25
36.6
111 in-lb
13 N-m
85 in-lb
9.6 N-m
N/A
N/A
69 in-lb
7.8 N-m
53 in-lb
6.0 N-m
N/A
N/A
M10
1.5
58.0
219 in-lb
25 N-m
167 in-lb
19 N-m
N/A
N/A
137 in-lb
15 N-m
105 in-lb
12 N-m
N/A
N/A
M12
1.75
84.3
32 ft-lb
43 N-m
24 ft-lb
33 N-m
99 ft-lb
134 N-m
76 ft-lb
103 N-m
20 ft-lb
27 N-m
15 ft-lb
20 N-m
90 ft-lb
122 N-m
68 ft-lb
92 N-m
M16
2
157
78 ft-lb
106 N-m
59 ft-lb
80 N-m
243 ft-lb
329 N-m
185 ft-lb
251 N-m
49 ft-lb
66 N-m
37 ft-lb
50 N-m
219 ft-lb
297 N-m
166 ft-lb
225 N-m
M20
2.5
245
152 ft-lb
206 N-m
116 ft-lb
157 N-m
475 ft-lb
644 N-m
361 ft-lb
489 N-m
95 ft-lb
129 N-m
72 ft-lb
98 N-m
428 ft-lb
580 N-m
326 ft-lb
442 N-m
M24
3
353
263 ft-lb
357 N-m
200 ft-lb
271 N-m
821 ft-lb
1113 N-m
624 ft-lb
846 N-m
164 ft-lb
222 N-m
125 ft-lb
169 N-m
740 ft-lb
1003 N-m
563 ft-lb
763 N-m
M30
3.5
561
520 ft-lb
705 N-m
395 ft-lb
536 N-m
1626 ft-lb
2204 N-m
1234 ft-lb
1673 N-m
325 ft-lb
441 N-m
247 ft-lb
335 N-m
1463 ft-lb
1983 N-m
1111 ft-lb
1506 N-m
M36
4
817
908 ft-lb
1231 N-m
688 ft-lb
933 N-m
2836 ft-lb
3845 N-m
2149 ft-lb
2914 N-m
567 ft-lb
769 N-m
430 ft-lb
583 N-m
2554 ft-lb
3463 N-m
1935 ft-lb
2623 N-m
Screw
Size
Linear Rail and Bearing Bolt Torque Specifications
V1-R3
Bolt Size
M4
M5
M6
M8
M10
M12
M14
M16
3
45
Bolt Strength Grade 12.9 (Standard Socket Head Bolt)
DRY (LUBED or LOCTITED)
N-m
in-lb
5 (4)
44 (33)
10 (8)
88 (66)
16 (12)
142 (106)
40 (30)
354 (265)
81 (60)
717 (322)
95 (70)
841 (630)
166 (124)
1,469 (1,100)
265 (200)
2,345 (2,760)
Visit us at www.Peddinghaus.com
ft-lb
4 (3)
7 (5)
12 (9)
29 (22)
59 (44)
70 (52)
122 (91)
195 (146)
PCD 1100/3C ATC
1. 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).
2. General Usage is considered bolting of low carbon hot rolled steel in non-fatigue type applications or when not otherwise
specified by Engineering.
3. Special Usage is considered bolting of hardened steels or alloys and/or fatigue type applications. Engineering is to indicate the
torque to be used on the 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. Be sure to check screw head contact stress as
discussed below.
4. Torques for Hex Head Cap Screws w/High Strength Washers (or Hex Flange Bolts) is also considered Special Usage. Again, be sure
to check screw head contact stress as discussed below.
5. For Cadmium plated screws, multiply the tabulated dry torque values by .80
6. For Zinc plated screws, multiply the tabulated dry torque values by 1.1
7. For fine threads, multiply the tabulated torque values by 1.12
8. This table does not apply to shoulder or low head screws.
46
4
V1-R3
Chapter 4: Maintenance &Chapter
Troubleshooting
1: Safety
PCD 1100/3C ATC
4.8.2 Screw and Bolt Torque Specifications—Standard
Grade 5 Hex
Unbrako-Socket Head
Torque
Induced Bolt
Stress
Thread Size
Zinc-Plated
Special Usage
General Shop Usage
(use when specified by
engineering)
General Shop Usage
32,000 PSI
100,000 PSI
20,000 PSI
Screw
Tensile
Area
Dry
Lubed or
Loctited
Dry
Lubed or
Loctited
Dry
Lubed or
Loctited
-
64 IN#
76 IN#
-
18 IN#
21 IN#
-
.0175 IN2
.0200 IN2
10
24
32
21 IN#
24 IN#
1/4
20
28
51 IN#
58 IN#
150 IN#
170 IN#
-
45 IN#
50 IN#
-
.0318 IN2
.0364 IN2
5/16
18
24
104 IN#
116 IN#
305 IN#
325 IN#
180 IN#
92 IN#
100 IN#
-
.0524 IN2
.0580 IN2
3/8
16
24
15 FT#
17 FT#
45 FT#
48 FT#
30 FT#
162 IN#
185 IN#
-
.0775 IN2
.0878 IN2
7/16
14
20
25 FT#
28 FT#
70 FT#
75 FT#
45 FT#
22 FT#
24 FT#
-
.1063 IN2
.1187 IN2
1/2
13
20
38 FT#
45 FT#
108 FT#
114 FT#
70 FT#
34 FT#
38 FT#
-
.1419 IN2
.1599 IN2
9/16
12
18
55 FT#
61 FT#
155 FT#
164 FT#
100 FT#
48 FT#
53 FT#
-
.1820 IN2
.2030 IN2
5/8
11
18
75 FT#
85 FT#
210 FT#
222 FT#
140 FT#
66 FT#
74 FT#
34 FT#
.2260 IN2
.2560 IN2
3/4
10
16
133 FT#
155 FT#
360 FT#
400 FT#
240 FT#
118 FT#
130 FT#
78 FT#
.3340 IN2
.3730 IN2
7/8
9
14
216 FT#
237 FT#
580 FT#
633 FT#
385 FT#
188 FT#
206 FT#
126 FT#
.4620 IN2
.5090 IN2
1
8
12, 14
320 FT#
355 FT#
225 FT#
860 FT#
916 FT#
570 FT#
283 FT#
304 FT#
189 FT#
.6060 IN2
.6510 IN2
1 1/8
7
12
458 FT#
513 FT#
320 FT#
1240 FT#
1383 FT#
825 FT#
400 FT#
449 FT#
266 FT#
.7630 IN2
.8560 IN2
1 1/4
7
12
650 FT#
700 FT#
450 FT#
1750 FT#
1883 FT#
1150 FT#
566 FT#
626 FT#
378 FT#
.9690 IN2
1.073 IN2
1 1/2
6
12
1124 FT#
1265 Ft#
775 FT#
3041 FT#
3275 FT#
2028 FT#
984 FT#
1106 FT#
658 FT#
1.405 IN2
1.581 IN2
Use Dry Torque
to Get
50,000 PSI PreStress for
Fatigued
Applications
Zinc Plated
V1-R3
1.
2.
3.
4.
5.
6.
Lubricated or Loctited torque = .667 x “Dry” torque. This will give an equal bolt stress to that of “Dry” torque.
“General Usage” indicates the use of 1020 type materials.
“Special Usage” indicates the use of heat treated materials, alloys, and/or fatigue type applications.
For cadmium-plated screws, multiply equivalent zinc-plated torque by 0.53.
For bare metal screws, multiply torque by 0.71.
This chart does not apply to shoulder or low head screws.
3
47
Visit us at www.Peddinghaus.com
PCD 1100/3C ATC
Usage Notes
• Calculate compressive stress “Sc” under bold head when using torque for “Hardened Materials” or for cyclic loading with high
forces. This will ensure that the material being bolted will not deform.
• Do not use fasteners smaller than 1/2” diameter where critical torque and stress is expected.
Head Dia.
Head Dia.
Hole Dia.
Non-heat
Treated
Steels
Chamfer OD
Hardened
Steels
Definitions:
“Wt” is the load (or force) in pounds on the screw, induced by torque.
“At” is the “screw tensile area” in inches squared.
“St” is the stress in the screw in PSI, induced by “Wt”.
“Sc” is the contact stress of the bolt head on the mating material. This should not exceed the yield point of the material.
“T” is the recommended torque in “foot #”.
Wt =
(T ft#)(60)
(nominal screw size)
St = Wt
At
Sc =
_____Wt _____
(head area - hole area)
Or (head area - chamfer area)
Note: actual applied bolt stress can vary by 20%.
48
4
V1-R3
Chapter 4: Maintenance &Chapter
Troubleshooting
1: Safety
PCD 1100/3C ATC
5.0 Spare Parts
Note
The following lists may be edited in the future based on actual parts used on the machine.
5.1 Standard Spare Parts
These are the most commonly needed spare parts for your machine and should be kept on hand to minimize down time. These are
considered to be wear parts, or are parts that have a history of failing over time.
Description
Quantity
Part Number
3
YD2308961
Laser, Transmitter/Receiver
1
YD2314919
Carriage, Linear Rail
2
YD2315029
Carriage, Linear Rail
2
YD2315028
Bearing, Pillow Block Dodge
1
YD2312294
Camrol
2
YD2310079
Camrol Bearing
2
YD2302670
Belt, Synchronous Gates (W– and Z-axis Position)
1
YD2315106
Prox Switch 12mm
2
YD2315418
Timing Belt (Y-axis Drilling)
1
YD2315104
Synchronous Belt (Y-axis Position)
1
YD2315105
Union, Rotary Deublin
1
YD2314133
Driver Sprocket
1
YD2315090
Prox Switch 12mm OD
2
YD2307493
Finger, Cat 40 Tool Gripper
1
YD184600090011
Finger with Key Cat 40
1
YD184600090012
Compression Spring
1
YD2311993
Filter Element
1
0165R010BN4HC
Air Valve
1
YD2314918
Valve, Directional—Blocked Center-8 Watt
1
YD2315448
Valve, Directional—A&BTOTANK-8 Watt Coil
1
YD2315449
V1-R3
Cyr-3-S Camrol
3
49
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PCD 1100/3C ATC
5.2 Additional Spare Parts Sources
Hydraulic Hoses
Type
Working Pressure (psi)
Parker #F451TC 3/8”
3000
Parker #F451TC 1/2”
3000
Parker #F451TC 3/4”
3000
Parker #F451TC 1”
3000
Parker #F451TC/67 1 1/4”
3000
Pneumatic Hoses
Type
Working Pressure (psi)
Parker or SMC Polyurethane 1/4” (.040” wall) Standard Air Tubing
120
Parker or SMC Polyurethane 3/8” (.062” wall) Standard Air Tubing
125
Parker or SMC Polyurethane 1/2” (.062” wall) Standard Air Tubing
90
When replacing any hydraulic or pneumatic hoses, it is recommended to replace them with the same brand and style (or equal). It
is also recommended that all hose tags are reproduced on both ends of the hose for future identification.
5.3 Ordering Spare Parts
When dealing with and contacting the Peddinghaus’ Spare Parts Department, have the appropriate piece part drawing or assembly
drawing in front of you prior to placing the call. Our sales technician will immediately be able to access the same assembly
drawing to synchronize the replacement part requirement.
Warning
Use only authorized Peddinghaus replacement parts. Failure to do so can reduce
the functionality or liability and safety of the system. This can lead to serious
injury or even death, not only to the machine operator, but also to other people
in the area.
5.4 Returning Spare Parts for Credit
No item that is returned to Peddinghaus Corporation will be accepted without prior authorization. The return authorization number
must be written on the outside of the package. If it arrives at our facility without a return authorization number, it will be refused
and returned to the sender.
To receive a return authorization number for a part, contact Peddinghaus Inside Sales for instructions and the number.
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6.0 Assembly
6.1 Handling
Extreme care and safety must be exercised when unloading your Peddinghaus Machine. Always use cranes and forklifts of
sufficient capacity with chains and cables of recommended design (refer to American National Standards Institute B30.9 or
European Standards Committee CEN/TC 168/prEN 818-1, -2, -8). The weights of the various elements are indicated on the Bill of
Lading.
Unloading the machine requires extreme caution and experience. Peddinghaus Corporation strongly recommends that a
professional rigger be employed to unload and place the equipment.
For components lacking lifting eyebolts, straps may be placed around the main frame members.
Caution
Threaded holes with or without lifting eyebolts may be provided. Holes are
provided in some plates that are of sufficient strength for lifting those
assemblies. Never use eyebolts or threaded holes located on cylinder assemblies
or electric motors for lifting the entire assembly. These eyebolts or tapped
holes are for lifting only those devices as individual components.
6.2 Identification of Components
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To facilitate the shipment and installation, your Peddinghaus machine will be shipped as one compact package, ready to be
installed. The major components of this package include
• 5 red shipping brackets
- Transformer Holding Bracket
- Control Console Holding Bracket
- Z-axis Slide to Main Frame Bracket
- Y-axis Slide to Main Frame Bracket
- W-axis Slide to Main Frame Bracket
• 1 Transformer
• 1 Control Console
• 1 Main Machine
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6.3 Support and Lifting Points
Use the 4 main machine lifting lugs when shipping or moving the entire machine. For components lacking lifting eyebolts, straps
may be placed around the main frame parts.
Warning
The crane, ropes, chains, and lifting equipment used in moving the components
must be rated for the specified carrying force. Never walk under hanging loads.
Minimum 13 feet (4m) long chains
Indicates
authorized
lifting points
Figure 6-1: Main Machine Lifting Points
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6.4 Machine Alignment and Leveling
Caution
All Peddinghaus machines are shipped with a protective rust inhibitor applied to
all unpainted surfaces, bearing rails, and pistons on hydraulic cylinders. This
inhibitor must be removed before machine use. To remove, use mineral spirits,
kerosene-soaked cloths, or vapor degreasing techniques.
Shipping Blocks
5 red shipping blocks are attached to different parts of the machine to prevent excess motion during shipping. These blocks must
be removed before the machine is put into operation. Note: Reserve these blocks, in the event that the machine should be moved
again, and replace the securing bolts after the blocks have been removed.
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Figure 6-2: Shipping Blocks
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Machine Leveling
Level and grout under the base of the machine as needed to level the machine. A transit should be employed and sightings should
be made along the passline rollers to accomplish this task. The final welding of the six (6) anchor plates to the drill’s base plate
should not occur until the Peddinghaus Service Technician has verified the leveling, elevation, and datum alignment.
Passline Details
All PCD 1100/3C drills have adjustable passlines.
Locking Bolt
Leveling Bolt
Anchor Plates
To adjust the passline:
• First, manipulate the large leveling bolts on
each of the machines to bring the machine to
the desired height.
• After the passline is set and the machine made
level, lock the machine in place by securing the
locking bolt.
Figure 6-3: Passline Adjustment
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6.5 Positioning and Joining of Components
6.5.1 Machine and Component Placement
After unloading the machine from its container:
• Remove the transformer from its shipping bracket and position it per the customer layout drawing.
• Remove the control console from its shipping bracket and position it per the customer layout drawing.
6.5.2 Check Machine Paint Coverage
The color scheme of Peddinghaus Corporation systems includes several types of acrylic and acrylic enamel paints. Although it may
not be possible to achieve the same original factory paint appearance, the guidelines below may assist with any general repainting
that may be required:
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•
Primer applied to all painted surfaces—gray automotive-type primer
Green paint applied to the machine’s main body—green automotive-type paint
Orange paint applied to certain moving elements—orange automotive-type paint
Coating applied over control console panels—clear urethane coating
Black paint on high-temperature parts—1200° F (649° C) high temperature black paint
(The original machine purchaser may have specified a certain color or paint other than our standard.)
These paints were specifically selected for several reasons:
• The basic color scheme is for Peddinghaus Corp. product registration.
• The quality of the paint product creates an easily cleanable surface over all parts.
• The orange color is used to designate and draw attention to certain moving machine elements.
• The high-temperature black paint offers protection for certain components that operate at above-ambient temperatures. It is
also used where thin-coat paint protection is required.
If repainting is required, follow the original machine paint scheme, and refer to these guidelines:
Orange machine elements should remain that color for general safety reasons.
Use high-temperature paints where above-ambient temperatures are encountered.
Do not allow paint to get into bushings, shafts, rotating or sliding mechanisms, or on guideways. Do not paint on grease fittings
or openings.
• Do not allow paint to get into electrical components, control buttons, limit or proximity switches, or switch light reflectors.
• Do not paint over any warning signs, labels, product information, control tags, instructions, or air filters.
• Paint should never interfere with the intended function of the machine or cause an unsafe operating condition.
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6.5.3 Loctite
Fasteners are Loctited to assure proper and safe machine operation. The maintenance department should not neglect these
practices during the repair or re-assembly of any Peddimat system.
Be certain to follow all instructions and safety precautions as stated by the Loctite Corporation when using their products.
Normal machine operation may cause a loosening of some fasteners, or maintenance may require the removal of some fasteners.
These may be reassembled with Loctite as follows:
• If previously Loctited, remove existing Loctite with a wire brush.
• Loctite acts as a lubricant and torque values should be based on this fact.
• On blind threaded holes, place the Loctite into the hole, not on the fastener.
• Because of the setting time of Loctite, use primer “N” for maintenance applications.
• For fasteners smaller than 1/4” (6.35 mm) thread, Loctite #222 Purple may be used.
• For fasteners 1/4” (6.35 mm) thread and larger, Loctite #242 Blue may be used.
• For fasteners 1/4” (6.35 mm) thread and larger that are made of high-strength alloy (UNBRAKO type), use Loctite #262 Red if
additional maintenance sheets indicate the use of this Loctite.
• Loctite #262 may be used for securing keys into keyways.
• Pneumatic/Hydraulic Seal 545 may be used to secure and seal air and hydraulic lines. Use Teflon tape on acetylene or oxygen
fittings. Do not use Loctite seal 545 or PST.
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6.6 Dismantling, Disposal, and Reassembly
Dismantling
If dismantling the machine to make a repair, take careful note of how parts fit together to aid in the reassembly process.
Warning
When dismantling any part of the hydraulic system, make sure all pressure is
relieved from the system prior to removing any components. Cylinders may drift
down due to gravity after the hoses are removed.
If the machine is taken out of commission and is to be scrapped, all hazardous components, including environmentally hazardous
material, must first be removed and disposed of properly according to local regulations. Care should be taken to sort the
components by the material types.
Material Disposal
Category
Circuit Boards
Hydraulic Hoses
Hazardous Material
Lead (Solder)
Microchips
Rubber
Use / Location
Inside Control Console
All hoses to cylinders and valves
Hydraulic Reservoir
Hydraulic Fluid
Oil
In Hydraulic Hoses
In Hydraulic Cylinders
In Hydraulic Manifolds
Lubricants
Lithium Grease
Bearings
Wiring
Plastic Insulation
All Electrical Wires
Misc. Electrical
Solenoids
Hydraulic Valves
Switches
Disposal
Hazardous materials should only be disposed of in a way that is not harmful to the environment. All local regulations must be
followed.
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Reassembly
Extreme care must be used for reassembly of components on your machine. All surfaces containing grease must be cleaned off and
coated with new grease. If you need any assistance during reassembly, contact the Peddinghaus Corporation Service Department.
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7.0 Installation
7.1 Installation Requirements
Refer to the General Arrangement Diagram (included along with the Peddinghaus price quote) for installation requirements and
foundation guidelines.
Note
Foundation Work is not included in the Peddinghaus scope of delivery.
Check the General Arrangement Diagram and local codes for installation specifications and standards.
Environmental Requirements
Generally, this machine should be installed only under the following conditions. If all of these conditions cannot be met, contact
Peddinghaus Corporation to discuss the discrepancies and how they will affect the machine.
•
•
•
•
•
•
•
•
Supply Voltage: 95% to 105% of nominal supply power voltage
Source Frequency: ±2 Hz of nominal
Ambient Temperature: 41° F (5° C) to 104° F (40° C)
Relative Humidity: 90% or lower (no condensation)
Altitude: Up to 3,280 ft (1000 m) above mean sea level
Atmosphere: Free from excess dust, acid fumes, corrosive gases, and salt
Avoid direct sunlight and/or heat rays, which could alter the ambient temperature of the machine
Do not expose the machine to abnormal vibration. Vibrations generated by the machine are considered normal and must not
be exceeded.
7.2 Required Installation Materials and Tools
The General Arrangement Diagram lists all materials needed for installation of your machine. Most materials required will be
shipped with the machine; however, you may need to provide some of the materials yourself.
The power unit will be shipped without hydraulic oil; you will need to supply your own oil. The General Arrangement Diagram will
indicate how much is needed for the installation.
You are also required to supply the anchor bolts for your system. The required size and quantity will be indicated on the General
Arrangement Diagram.
The following tools will be needed to complete the installation:
Overhead crane
4 lifting hook chains at least 13 feet (4m) long, with shackles
Sight level (optical transit)
Chalk line
Pry bar
Small sledgehammer
Power hammer drill with bit for anchor bolts
(1) 18mm, (1) 1 1/2 inch, (1) 2 1/2 inch wrenches or sockets
(2) 3” (150mm) or larger “C” clamps (or larger)
(2) 6” (300mm) or shorter mini hydraulic , mini screw, or planer jacks
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7.3 Installation Procedures
7.3.1 Electrical Connection
The system location and alignment must be checked by a Peddinghaus Service Technician before any electrical connections are to
be made. At that time, it may only be connected by an electrician. The connection must be made according to the electric
schematics included in the instruction packet. All Federal regulations and any special regulations of your local supplier must be
observed.
Caution
Compare the operating voltage of the system to the available main voltage. The
operating voltage of the system can be found on a label on the switching
cabinet, located on the hydraulic power unit. The voltage noted is phase-tophase (i.e., the voltage between the phases L1-L2-L3). The phase-to-phase
voltage must not exceed the maximum permissible value of 480 VAC ±10%.
The machine is designed to operate at 380, 415, or 480 VAC by adjusting the primary taps on the supply transformer. If other
voltages are desired, an optional step-up or step-down transformer will be required.
7.3.2 Fusing on the Construction Site and Supply Lines
The fusing and the supply lines on the construction side must be provided and installed by an electrician according to the layout.
All Federal regulations and any special regulations of the local supplier must be observed.
The supply line for a connected load of 63 kVA must have sufficient connection length above the floor at the location marked in
the layout. A good earth ground is required to achieve satisfactory operation of PC/CNC systems in an industrial environment. Refer to Federal and local regulations for acceptable grounding procedures. See the following figure for the grounding location of the
machine.
Warning
Do not energize power to the electrical cabinet until the Peddinghaus Service
Technician has checked the installation. This machine must be installed in
compliance with all appropriate local and international codes.
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Main Power
Supply
Ground
Terminal
Figure 7-1: Electric Enclosure
7.3.3 Hydraulic Connections
All of the hydraulic connections to your machine have been made at the factory, except for the hydraulic hose connection to the
power unit. The pressure and return line hoses will need to be connected to the appropriate ports on the power unit and on the
machine. The ports are labeled for identification and are different sizes, so that the hoses will only fit in the ports they are
intended for.
7.3.4 Pneumatic Connections
This machine requires compressed air in order to function correctly. The compressed air is connected to the machine at the FR
(filter/regulator) unit. The connection port to the FRL unit is 1/2” NPT.
Pneumatic Connection
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Figure 7-2: Pneumatic Connection
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7.4 Assembly and Installation Inspection
Once you believe you have the machine assembled correctly and approximately in place (but not anchored), contact Peddinghaus
Corporation to have a Service Technician come out and complete the installation of your machine. He will first ensure that the
electrical power to the system is hooked up correctly. He will then check to ensure the machine is aligned correctly. Once the
machine is in place, and the alignment is approved, the machine can be anchored to the foundation and installation can be
completed.
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8.0 Packaging & Storage
8.1 Packaging Requirements
When packaging your machine for storage or transport, the packaging should be secure and neither it nor any part of the machine
should be allowed to move. Extra care must be taken to ensure the machine is not damaged. The machine should be protected
from moisture.
8.2 Methods of Handling
Exercise extreme care when handling your machine. It is a precise machine and any mishandling can cause a loss of accuracy.
Most components of your system are too heavy to be lifted by hand; therefore, additional equipment should be used. A crane is
recommended for lifting and moving the components of your system. A forklift may be used for some components, but only if it
can be done so safely.
Refer to the Assembly chapter for lifting data and points on this machine.
8.3 Protection from Unwanted Movement
To prevent damage to the machine or injury to those working on or around the machine, protect the machine from sudden impacts
and unwanted movement.
Some components of your machine can be easily disassembled for convenient securing and packaging. The in-feed sections can be
removed from the main machine. All small loose parts should be packaged together to prevent loss.
All moveable parts should be blocked or secured to ensure that they don’t move during transport or in storage. The upper shear
blade should be blocked so that it cannot drift down. The punches should be secured so that they cannot move.
8.4 Labeling
All packages and components should be identified with a label to ensure no parts are lost. In addition, all dangerous and
hazardous objects should be labeled appropriately.
8.5 Storage Requirements
Store the machine in a low-humidity environment to prevent rust from forming. We recommend a protective coating be applied to
all exposed metal surfaces to prevent rust formation.
Do not store your system outside. Only store it indoors where it will be protected from moisture and natural elements.
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Drain the hydraulic reservoir to prevent spillage.
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8.6 Storage Space
96.0 inches
(2438mm)
227.0 inches
(5767mm)
204.0 inches
(5081mm)
96.0 inches
(2438mm)
Note: Maximum operating height of the machine can reach 112.0 inches (2845mm)
Figure 8-1: Storage Space
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9.0 Basic Machine Operation
9.1 Siemens CNC Control General Information
The Siemens CNC control is a VERY robust system. A detailed explanation of its many facets far exceeds the scope of this manual.
This manual will try to provide a brief and simple explanation of a few basic concepts needed for general operations. A complete
listing of features with descriptions can be found in the supplied Siemens documentation.
One general concept that all users need to understand is the concept of system memory. The Siemens CNC control is a PC based
system complete with a PC type hard disk. There is plenty of extra hard disk space (HD memory) that can be used for part program
storage. In addition, the control has extra “high speed” memory not found on a normal PC that provides additional electronic RAM
memory for part program storage and execution. This additional memory is referred to as NC memory. Generally, a part program
must be loaded in NC memory before it can be selected as the active program and executed by the machine.
The HMI (Human Machine Interface) software treats HD memory and NC memory as one large “virtual” storage container. The HMI
provides the tools to copy, rename, and delete program files as well as move them from HD to NC and NC to HD. The only way to
distinguish whether a part program is located in NC memory vs. HD memory is the “Loaded” column in all part program listings. If
an “X” appears in the “Loaded” column the part program is located in NC memory, otherwise the part program is located in HD
memory.
This “dual memory” concept can cause problems for “normal” software applications (such as Peddinghaus’ Peddimat programming
system) that “see” only the HD memory and cannot “see” the NC memory. Example: If a part program is located in NC memory and
Peddimat creates a new part program with the same name in HD memory, there is now a conflict. The HMI will represent this by
displaying an “!X!” in the “Loaded” column in all part program listings. If this situation occurs the 840Di will not allow either of
these part programs to be selected and executed. To correct the conflict the normal HMI tools must be used to delete the file,
which will in fact delete only the part program located in NC memory, leaving the part program in HD memory.
Another important concept to know about is “Operating Areas”. An “Operating Area” is a functional area of the HMI software and
has nothing to do with the traditional “Operating Mode” described below. However, when the “Machine” operating area is active,
the current operating mode will affect what information is displayed to the operator and what softkeys are available. Other
operating areas include Services (where part programs are managed), Diagnosis (troubleshooting), Start-Up (high level
configuration data) and Parms (general configuration parameters). Some of these operating areas will be discussed later in this
manual. To switch from one operating area to another, press the “Menu Select” button then choose the desired operating area
softkey.
Status LEDs
Power
Temp
Softkeys
Alpha key
group
Numerical
key group
Cursor
key group
Control
key group
USB front
interface
Softkeys
Recall
Machine area
ETC key
Menu Select
Hotkeys
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Figure 9-1: Siemens 840 Di Operator’s Panel
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Figure 9-2: Machine Control Panel
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9.2 Operating Modes
The Siemens CNC has 4 different main operating modes that can be selected via appropriately labeled buttons on the machine
control panel. This manual will discuss 3 modes. The 4th mode, “Teach In”, is beyond the scope of this manual:
“JOG” - Manual movement of the machine
“MDI” - Manual creation and execution of programs
“AUTOMATIC” - Execution of programs in a continuous cycle
9.3 Jog Mode
Enter Jog mode by pressing the “Jog” button on the machine control panel. Jog mode has two optional sub-modes: “Repos” & “Ref
Point” - that are available via buttons located to the right of the “Jog” button. “Repos” is used to return an axis to its prior
position if it has been jogged during an interruption of an automatic program. “Ref Point” is used to manually reference an axis
and is not typically used on Peddinghaus machines.
To jog an axis manually while in Jog mode:
• Make sure that neither sub-mode (Repos or Ref Point) is active by looking at the indicator lamps above the sub-mode buttons.
If a sub-mode is active, press the “Jog” button a second time.
• Next, select the desired axis by pressing the appropriate axis button on the machine control panel.
• Jog the axis by pressing and holding the “+” & “-“ buttons on the machine control panel. To jog at a faster pace additionally
press the “Rapid” button.
9.3.1 Jog Mode—Incremental Axis Move
To jog an axis by specific increments:
• Enter Jog mode by pressing the “Jog” button on the machine control panel.
• Select the desired axis by pressing the “X” or “Y” button on the machine control panel.
• Select the desired incremental distance by pressing one of the pre-set distance buttons labeled 1,10,100,1000,10000 (all
distances are in thousandths of millimeters, so 1000 equals one millimeter).
• Last, press the “+” or “-“ button. The axis will move the desired distance in the desired direction.
To move a variable distance:
• Press the “VAR” button.
• Next (with the “Machine” operating area active) set the desired distance by pressing the “INC” softkey, entering a value (in
thousandths of millimeters), and pressing the “Input” key, followed by the “+” or “-“ button.
9.3.2 Jog Mode—Automatic Tool Changer
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To manually jog the Automatic Tool Changers:
• Press and hold the tool mode button until the message “Manual Tool Mode” is displayed on the control screen.
• Press the “auto” button on the control.
• Press the desired axis button that corresponds with the tool changer that is to be moved (ex. Select the “w” axis pushbutton if
the w tool changer needs to be jogged).
• The “tower” + and – buttons now control the movement of the selected tool changer.
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9.4 MDI Mode
Enter MDI mode by pressing the “MDI” button on the machine control panel (“MDA” button on early versions). If the “Machine”
operating area is active, a small editable window titled “MDI” will appear in the lower left quadrant of the display. Programs of
any type can be manually entered and executed here. Program execution is identical to Automatic mode with normal use of the
Cycle Start, Cycle Stop and Single Block buttons.
An advanced level of understanding of Siemens NC language and machine functionality is required to write fully functional part
programs in MDI mode. This is not recommended. However, only a basic understanding of machine functionality is required to
perform some basic operations. At the end of this chapter is a list of helpful M codes commonly used in MDI mode.
9.5 Automatic Mode
Enter Automatic mode by pressing the “Auto” button on the machine control panel. If the “Machine” operating area is active, a
small non-editable window titled “Current Block” will appear in the lower left quadrant of the display. The currently selected part
program name will be displayed in the upper right corner of the screen. If no part program is currently selected, the default empty
program MPF0 will be shown.
9.5.1 Part Program Selection
In Automatic mode (with the “Machine” operating area active), press the “Program Overview” softkey. You may need to press one
of the storage location softkeys (ie. Work Pieces or Part Programs) to locate the desired part program. Use the
&
arrow
buttons to highlight the desired part program. Press the “Select” softkey. If the part program is already loaded into NC memory it
will be selected as the currently active program. If the part program is loaded into HD memory it will automatically be moved into
NC memory first and them be selected as the currently active program.
9.5.2 Load HD » NC
In Automatic mode (with the “Machine” operating area active), press the “Program Overview” softkey. You may need to press one
of the storage location softkeys (ie. Work Pieces or Part Programs) to locate the desired part program. Use the
&
arrow
buttons to highlight the desired part program. Press the “Load HD » NC” softkey. This will move the desired part program from HD
memory to NC memory; however, it will NOT become the currently active program.
9.5.3 Unload NC » HD
In Automatic mode (with the “Machine” operating area active), press the “Program Overview” softkey. You may need to press one
of the storage location softkeys (ie. Work Pieces or Part Programs) to locate the desired part program. Use the
&
arrow
buttons to highlight the desired part program. Press the “Unload NC » HD” softkey. This will move the desired part program from
NC memory to HD memory. If the part program was the currently active program it WILL be unloaded and a default “empty” part
program MPF0 will be set as currently active.
9.5.4 Start Cycle
In Automatic mode (regardless of what operating area is active) pressing the Cycle Start button (located on the machine control
panel) will cause the machine to start execution from the current block.
9.5.5 Stop Cycle
In Automatic mode (regardless of what operating area is active) pressing the Cycle Stop button (located on the machine control
panel) will cause the machine to stop execution at the current block.
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9.5.6 Single Block Execution
In Automatic mode (regardless of what operating area is active), pressing the Single Block button (located on the machine control
panel) will cause the machine to stop execution at the end of each block. Cycle Start will start the execution of the next block.
Pressing the Single Block button a second time will return the control to full automatic execution.
9.5.7 View Currently Selected Part Program
In Automatic mode (with the “Machine” operating area active) press the “Program Blocks” softkey. The “Current Block” window
will change into a non-editable scrollable window displaying the entire part program. The window is somewhat narrow and some
blocks may be “wrapped” onto a second or third line.
9.5.8 Edit Currently Selected Part Program
In Automatic mode (with the “Machine” operating area active) press the “Correct Program” softkey. A full screen block editor will
now display the entire part program. Changes can be made if desired.
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Caution
Only experienced NC programmers with specific knowledge about this machine
should manually edit a part program.
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9.6 User Views
In the “Start Up”, “Machine Data” area there is a sofkey labeled “User Views” that allows OEMs to create small subsets of General
MD, Channel MD, Axis MD, Drive MD, etc… and put them on individual custom screens. These same MD variables are always
available in the big all inclusive Siemens list but Users Views allows us to create small groups of important or often used MD
variables. The PCD C has 2 such User View screens so far.
9.6.1 User View #1—“Ped 1”
This User View contains some Channel MD, Infeed (ALM) MD and Axis MD. All of these items are read/write.
•
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•
•
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•
•
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20150[13] GCode Reset Values – Use this parameter to change the display of axis position to either inches or millimeters. Set
the value to “2” for millimeters. Set the value to “3” for inches. (Service Access Level)
p10 – Infeed commissioning parameter filter - Setting to a value of “1” allows voltage change parameters to be modified.
p210 – Drive Unit Line Supply Voltage – Indicates the incoming voltage (480v, 400v, 230v, etc..)
p211 – Rated Line Freq – Indicates the incoming frequency (50 Hz, 60 Hz)
p3410 – Infeed Identification Method – 0 = ID Complete, 3 = Perform ID on next start-up
X – 32100 – AX_MOTION_DIR – Similar to BDL D Material Flow (1 = R->L, -1 = L->R)
X – 34100[0] – REFP_SET_POS[0] – Normal X home position (mm)
X – 34100[1] – REFP_SET_POS[1] – Rev Reference home position (mm)
X – 31010[0] – ENC_GRID_POINT_DIST[0] – Entry meas disk scalefactor
X – 31010[1] – ENC_GRIP_POINT_DIST[1] – Exit meas disk scalefactor
YZW – 34100[0] – REFP_SET_POS – Axis home position
YZW – 34210[2] – ENC_REFP_STATE – Used to set absolute position.
YZW – 36100 – POS_LIMIT_MINUS – Soft limit minus
YZW – 36110 – POS_LIMIT_PLUS – Soft limit plus
9.6.2 User View #2—”Ped 2”
This User View contains some Drive MD for the 6 PLC axes.
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YZW SPIN p2600 – Used to set offset after spindle orientation in tenths of degrees.
YZW FEED p2599 – Used to set axis home position (similar to REFP_SET_POS) in thousandths of mm
YZW FEED p2507[0] – Set to (2) to apply p2599 parameter to axis home. Changes to (3) automatically.
YZW FEED p2580 – Soft limit minus
YZW FEED p2581 – Soft limit plus
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Chapter 9: Basic Machine
ChapterOperation
1: Safety
PCD 1100/3C ATC
10.0 Part Program Management
The “Services” operating area is used to manage part programs. From here, part programs can be copied from diskettes, copied
from NC or HD memory, renamed, or deleted. Although none of these should be attempted on the currently selected executing
part program, they can be applied to other part programs while the machine is running. In addition, the “Services” operating area
can be used to load part programs into the NC memory from HD memory and unload part programs into HD memory from NC
memory.
Note
The “Services” operating area cannot be used to “select” the active part program.
Like most operating areas, there are different sub-levels, screens, and menus in the “Services” operating area. If one of these sub
-levels is active and a different operating area is activated, it will remember which sub-level is active and return there when the
“services” operating area is re-entered. If necessary, press the Recall button (^) to move up one level at a time, or the ETC button
(>) to see additional menus.
10.1 Copy Part Program
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•
Enter the Services operating area.
Enter the Manage Data sub-level by pressing the “Manage Data” softkey. A Source file list will appear. If needed, the
“Programs/Data”, “Disk/Card”, and “Clipboard” softkeys can be used to change which source is displayed. Use the ↑, ↓,
“Input”, and “Select” buttons to navigate the source and select the files to be copied.
Press the “Copy…” softkey. The display will split horizontally, with the “source” on the top and the “target” at the bottom. If
needed, the “Programs/Data”, “Disk/Card”, and “Clipboard” softkeys can be used to change which target is displayed. Use
the ↑, ↓, “Input”, and “Select” buttons to navigate the target and highlight the target location.
Press the “Insert” softkey. The file or files will now be copied. If problems arise, a notification will appear along with any
appropriate action softkeys.
10.2 Rename Part Program
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•
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Enter the Services operating area.
Enter the Manage Data sub-level by pressing the “Manage Data” softkey. A Source file list will appear. If needed, the
“Programs/Data”, “Disk/Card”, and “Clipboard” softkeys can be used to change which source is displayed. Use the ↑, ↓,
“Input, and “Select” buttons to navigate the source and select the file to be renamed.
Press the “Properties” softkey. A file properties page will appear with the Name field highlighted by default.
Type the new name using the alphanumeric keys. Press OK to complete.
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PCD 1100/3C ATC
10.3 Delete Part Program or Programs
•
•
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Enter the Services operating area.
Enter the Manage Data sub-level by pressing the “Manage Data” softkey. A Source file list will appear. If needed, the
“Programs/Data”, “Disk/Card”, and “Clipboard” softkeys can be used to change which source is displayed. Use the ↑, ↓,
“Input”, and “Select” buttons to navigate the source and select the files to be deleted.
Press the “Delete…” softkey. A list of the files to be deleted will appear, along with the appropriate confirmation softkeys.
Select “Yes” to confirm file deletion individually, or “Yes All” to confirm all of the file deletions at once.
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Chapter 10: Part Program
Chapter
Management
1: Safety
PCD 1100/3C ATC
11.0 Machine Operations
11.1 Manual Pushbuttons
11.1.1 Power On
The lighted “Power On” button located between the Operator’s Panel and the Machine Control Panel is used to reset the e-stop
circuitry (hardware safety relays) after an E-stop. Use additional machine control panel buttons to clear remaining NC faults.
11.1.2 E-stop Buttons
There are several E-Stop buttons located around the machine and one E-Stop button located on the machine control panel.
Pressing any one of these buttons will immediately stop the machine in the event of an emergency.
To restore machine functions after an E-Stop event, clear all “tripped E-stop switches by either firmly pulling on the button or
giving it a slight twist, depending on the switch type). The “Power On” button must be pressed. The “Fault” button must be
pressed until its lamp goes off. Finally, press the “Reset” button.
11.1.3 Fault
Press to clear most “normal” status and error messages including safety stop and E-Stop events. Some events may require the
pressing of additional buttons to clear messages.
11.1.4 Tool Mode
Use this button to toggle between the 5 available tool modes (Auto, Off, Mark, Test & Tool Manual). The first button press will
always select “Off Mode”, subsequent presses (within 3 seconds) will toggle through the remaining modes. When a new tool mode
is selected, a notification message is displayed briefly on screen. The LED above the pushbutton indicates the active tool mode.
• Auto mode - All drilling and Signoscript commands are executed normally. LED is ON.
• Off mode - All drilling and Signoscript commands are ignored. LED is OFF.
• Mark mode - Drills will only mark the material, Signoscript commands are ignored. LED flashes at 1/2 second interval.
• Test mode - Drills will extend for a short time to indicate each drill command, Signoscript commands are ignored. LED flashes
at 1 second interval.
• Tool Manual mode – Allows for the option to change tools manually without using the ATC. This mode also allows jogging of
the ATC in and out, axis feeds, and rotation of spindle motors. The LED flashes at a 1 second interval (to access this mode,
press and hold the Tool Mode button until the message “Manual Tool Mode” appears at the top of the display screen ). See also
section 13.9, “Tool Change Procedure.”
11.1.5 Hyd PU
Use this pushbutton to toggle hydraulic pump on or off.
11.1.6 Entry VC Disable
Use this pushbutton to enable or disable the entry vertical hold-down during automatic operation.
11.1.7 Exit VC Disable
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Use this pushbutton to enable or disable the exit vertical hold-down during automatic operation.
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11.1.8 Speed OR & Feed OR
If it becomes necessary to increase or decrease the drilling speeds or feeds for all drills (due to varying material hardness, tool
condition, etc.), this can be done with the “Spindle Master Override %” knob and the “Speed Override” or “Feed Override”
pushbuttons. Turn the “Spindle Master Override %” knob to the desired override % (50% - 120%), then press the “Speed Override”
pushbutton to apply the override to drilling speed or the “Feed Override” pushbutton to apply the override to drilling feed. There
are parameters (discussed later in this manual) to calibrate the individual spindle speed & feed valves.
11.1.9 Reset
When pressed, the “Reset” pushbutton will reset the active program to line #1, the spindles will retract, and all clamps and holddowns will open.
11.1.10 Entry Jog Enable and Exit Jog Enable
Since the horizontal clamps are independent from one another the “Entry Jog Enable” and “Exit Jog Enable” pushbuttons are used
to determine which horizontal clamps will move when the “Tower +” and “Tower –“ are pressed.
E-Stop
Exit VC
Disable
Reset
Entry VC
Disable
Hyd PU
Speed OR
Tool Mode
Fault
Exit Jog Enable
Entry Jog Enable
Feed OR
Tower +
Tower -
Figure 11-1: Pushbutton Locations
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Chapter 11: Machine
Chapter
Operations
1: Safety
12.0 General Configuration Parameters
12.1 Miscellaneous Parameters
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Hydraulic Heater Enabled—Set this value to 1 if the hydraulic power unit is equipped with an automatic heater. Otherwise set this
value at 0. (Service)
Hydraulic Cooler Enabled—Set this value to 1 if the hydraulic power unit is equipped with an automatic cooler. Otherwise, set this value
at 0. (Service)
Hydraulic Full Pressure Time (milliseconds) - Sets the length of time allowed for the hydraulic unit to reach full system pressure. Most
of the machines’ hydraulic systems will delay until this time elapses. (Service)
Hydraulic On Time Current (hours) - Keeps track of the number of hours the machine has been working since the last time this
parameter has been reset. (User)
Hydraulic On Time Total (hours) - Keeps track of the total number of hours the machine has been working. (Service)
Type—This machine offers 3 different methods of finding the end of the material when performing an X axis reference. The number
entered in this parameter determines what method will be used: (User)
0 (Normal) – The Z/W axes move to the height determined in the part program and remain there for the duration of the reference
routine. This applies to all square cut material.
1 (Probe) – The web probe cycles during the reference routine to find the true web location of the beam. The Z/W axes move to
the true center of the beam’s web and remain there for the remainder of the reference routine. This applies to pre-coped beams
where the web extends beyond the flanges.
2 (Scan) – The Z/W axes move first to the height set in the “Scan Height” parameter. The X reference routine then uses a
sophisticated sequence of moves to find the longest point of an irregularly shaped beam. This applies to pre-coped beams where
the flange above or below the web extends beyond the web or to flange mitered beams.
•
•
•
•
•
•
Scan Height (millimeters) - This parameter determines the default Z & W axis position at the beginning of the special “scanning” X
reference routine. This parameter functions ONLY when the “Type” is set to 2. (User)
X Ref Switch – Use this parameter to select which X-axis Reference switch will be used during the X Reference cycle. To use the
“Primary” switch (located near the Z & W spindles) set this parameter to “1”. To use the “Secondary” switch (located on the exit side
of the machine near the measuring disk), set this parameter to “0”. (User)
X Ref Pos - Secondary (mm) – Use this parameter to adjust the X axis “home” position when using the “Secondary” switch. See the
section later in this manual concerning X axis “home” position for details about how/when to change this value. (Service)
Signomat1 Enabled—Set this value to 1 to enable optional Signomat logic, or set this value to 0 to disable optional Signomat logic.
(User)
Meba 1140/1250 Saw Enabled—Set this value to 1 to enable optional 1140 or 1250 (straight cut) saw logic, or set this value to 0 to
disable. (User)
Meba 1020/1270 Miter Saw Enabled—Set this value to 1 to enable optional 1020 or 1270 (miter cut) saw logic, or set this value to 0 to
disable. (User)
12.2 Clamp Parameters
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Entry Horizontal Clamp Scale—Feedback units/mm of the clamp position feedback.
Entry Horizontal Clamp Offset (mm) - The mm of offset to apply to the clamp position.
Exit Horizontal Clamp Scale—Feedback units/mm of the exit clamp position feedback.
Exit Horizontal Clamp Offset (mm) - The mm of offset to apply to the exit clamp position.
Allowable Width Deviation (mm) - If deviation is exceeded when clamped, a warning is issued.
Enable Automatic Clamp Pressure—Set this value to 1 if you want the machine to automatically determine horizontal and vertical clamp
pressures based on the information supplied by the part program. Set this value at 0 to manually set the clamp pressures. (User)
Vertical Clamp PSI (Manual) - Set this value (in pounds / inch2) to the desired pressure when the automatic clamp pressure has been
disabled. (User)
Horizontal Clamp PSI (Manual) - Set this value (in pounds / inch2) to the desired pressure when the automatic clamp pressure has been
disabled. (User)
V to H Pressure Ratio—Set this value to the desired ratio (vertical : horizontal) of clamp pressured that should be calculated when the
automatic clamp pressure is enabled. (Example: a set value of 0.75 will set the vertical pressure at 75% of the calculated horizontal
pressure.) (User)
Measuring Disk Height Scale Factor—Feedback units/mm of the position feedback.
Measuring Disk Height Offset (mm) - The mm of offset to apply to the disk position.
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12.3 Tool Changer Parameters
•
•
•
•
•
Y/Z/W Current Tool in Spindle (0-5) – What tool is currently in the spindle.
Y/Z/W On Tool Position (mm) – Spindle feed position where tool groove is aligned with magazine tool holders. For Y & W this
dimension is relative to feed axis zero(0). For Z this dimension is relative to the current position of the right horizontal clamp
(since the tool magazine is mounted to the right clamp).
Y/Z/W Tool #1 Gage (mm) – Axis gage position where spindle is aligned with tool position #1.
Y/Z/W Tool Spacing (mm) – Nominal distance between tools in magazine.
Y/Z/W ToolChanger Enable – 1= Tool changer is enabled; 0= Tool changer is disabled.
12.4 Spindle Parameters
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Y/Z/W Drill Counter—There are 3 separate drill counters, 1 for each drilling surface (Y, Z, and W). These counters display the
number of holes completed during part program execution and reset themselves to 0 when the part program completes. If a
part program ends prematurely for any reason, you may need to manually reset the drill counters to 0. Also, if a part program
needs to be restarted after some holes have already been drilled, you may need to set the drill counters to the proper values.
(User)
Tool Wear Reminder Enable—When set to 1, each completed drill sequence increments the specific spindle’s wear reminder
count. Once this count reaches the wear reminder limit, the control will display a warning message. This message will not stop
drill operation and can be closed by pressing the “Fault” pushbutton. When set to 0, the control does not keep track of the
wear reminder count. (Service)
Drill Lubrication Enable—Set to 1 to activate through-the-spindle lubrication during all drill operations. Set to 0 to disable all
drill lubrication. (User)
Lubrication Frequency (milliseconds) - Set this value to the frequency of lubrication pulses desired when the drill lubrication is
enabled. (User)
Air Off Delay Time (milliseconds) - Set this value to determine how long the through-the-spindle air system should remain on
after a drill cycle is completed. (User)
Mark Depth (mm) – Depth of mark in millimeters.
Auto Reset Tool Length Enable – 1 = all tools (of type 0 [Drill]) will have their length set to 0.0mm automatically at the end of
each program thus causing a probe sequence when the next hole is drilled. 0 = tool lengths are not reset and no probe
sequence is performed. The operator is thus responsible for resetting tool lengths when they change.
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Chapter 12: General Configuration Parameters
12.5 Y/Z/W Wear Parameters
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T1-T5 Wear Reminder Count—When “Tool Wear Reminder” is enabled (see section 12.3), this value increments after each drill
cycle. Operators can modify this value as needed. (User)
T1-T5 Wear Reminder Limit—When “Tool Wear Reminder” is enabled (see section 12.3), this set value determines when the
Wear Reminder appears on the display screen. Operators can modify this value as needed. (User)
T1-T5 Usage (mm) - The total amount of material drilled (in linear mm). This value is automatically set to 0 when the “Wear
Reminder Count” is reset to “0”.
12.6 Y/Z/W Tool Parameters
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T1 – T5 Length (mm) – The length of the tool as measured from the face of the spindle to the tip of the tool. Type 0 tools
(Drills) can have their lengths reset to 0 after each program (depending on “Auto Reset Tool Length Enable” parameter). Drills
with a length of 0 will probe the material on first use.
T1 – T5 Extra Depth (mm) – This parameter has different meanings depending on tool Type.
Type 0 (Drill) – Additional depth past theoretical material thickness that drill should travel (see item B in figure 12-1).
Type 1 (Countersink) – Compensation depth used to “dial in” programmed depth
Type 2 (Tap) – Length of tap’s “lead in” (ie. Beginning of tap without full threads)
Type 3 (Signo) – How far to compress signoscript spring mechanism while in use
T1 – T5 Type (0=D, 1=CS, 2=T, 3=Sig)
0 = Drill
1 = Countersink tool
2 = Tap
3 = Signoscript tool
12.7 Y/Z/W Spindle Parameters
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Fast Feed Rate (mm/min) – Feed rate to use during all rapid movements.
Start Feedrate Position (mm) – Sets the distance above the material to switch from rapid to programmed feed (see item A in
figure 12-1).
Short Return Position (mm) – Distance above the material to return after a drill (see item C in figure 12-1).
Enable Breakthrough Detection—Set this value to 1 to enable the Peddinghaus Smart Spindle technology. Set this value to 0 to
disable this technology and drill beyond the material’s surface. (User)
Breakthrough Min Depth (%) - This value represents the percentage of the full material thickness that the drill must travel
through before breakthrough detection will activate (see item D in figure 12-1). (User)
Breakthrough Correction Mult.—This is the multiplier applied to the unloaded spindle utilization current used for SmartSpindle
II breakthrough detection.
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Figure 12-1: Drill Spindle Parameters
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12.8 Optional Parameters for MEBA Saw with Epis Control Interface
The following parameters are used if your PCD 1100/3C ATC is interfaced with a MEBA Saw with Epis Control for tandem operation:
• MEBA Saw with Epis Control Enabled – This parameter allows the proper PLC logic to be executed if a MEBA Saw with Epis
Control is to be run in tandem with the drill. When the saw is present and set up to interface with the drill, set this parameter
to “1”. If no saw is present, or it is set up for independent operation, set this parameter to “0”.
• X Move at Saw Bottom—Epis Only—This parameter allows the X-Axis of the drill to move the material slightly when the saw
reaches the bottom of its cut. This eliminates the saw blade catching on material as it is moved from the bottom of its cut to
its short return position. The theory of operation is as follows:
1)
A normal part program with saw cut is run (M49).
2)
The beam is clamped, enters the drill, is processed and then moves into position for its saw cycle.
3)
The saw begins its cut and continues until it reaches the bottom of its stroke. At this point, the material should
be completely cut.
4)
The saw now remains in the down (bottom of stroke) position.
5)
While the saw is in the down position, the drill’s X-Axis can now move the beam a maximum of 10 mm to clear
material away from the saw blade.
6)
After the X-Axis move is complete, the saw will resume its normal cutting routine and raise above the beam
(allowing the normal process to continue).
Operational Notes:
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The distance that the X-Axis moves can range from 0 to + / - 10 mm. This is found in the parameter screen next to “X Move at
Saw Bottom - Epis Only”. This distance should only be set by a qualified operator familiar with the machine’s operation.
Additional important items related to the X-Axis move are machine material flow direction and saw placement. Since the
movement can be done in the + or – direction, it is CRITICAL that a + move be done when the saw is on the entry side, and a –
move when the saw is on the exit side. For example, if the saw is on the entry side then the parameter would be 10. If on the
exit side, the parameter would be -10. This value can be less than 10 but no more. If the value is entered incorrectly, such as
a “minus” (-7) instead of a “plus” (7) and the saw is on the entry side, the X-Axis will try to move the beam back into the saw
and it will crash, causing damage to the equipment.
If the x-axis move is not wanted or required, then a value of “0” should be entered into the parameter. Having a “0” here
allows the saw to make its cut and return as normal without any pause at the bottom.
The x-axis move will not occur if the drill clamps are open.
Note
The MEBA Saw Interface parameters must only be set or changed by a Peddinghaus
Corporation Field Service Technician or a qualified operator familiar with operation of the
tandem system that has read and understood this manual. Programming errors can result in
damage to the machine.
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Chapter 12: General Configuration Parameters
PCD 1100/3C ATC
13.0 Basic Operations
13.1 Calibrate the X-axis
X-axis calibration is a method of accurately relating actual distance moved to distance reported by the measuring device. Since the
X axis has two separate measuring devices (entry & exit), each must be calibrated individually and separately. Since the drill
switches automatically from entry to exit encoder over the course of running an automatic program it is NOT possible to perform
an X axis calibration while running a part program.
Calibration vs. Home Position – It is important to understand the difference between axis calibration and axis home position. Axis
calibration scales linear travel from one tool operation to the next and can be an effective adjustment when two separate drilling
operations are not located accurately from each other along the respective axis. Axis home position sets a “starting point” for
measurement and can be an effective adjustment when drilling operations are accurately located from each other but are mislocated (along the respective axis) from the edge of the raw material.
Caution
The axis calibration must be accurate before you adjust the axis home position.
Failure to do so may damage the machine permanently.
To calibrate the X-axis:
• Record the original scalefactor values (see the “Axis Data” section of the general configuration parameters.
• Load a long (minimum 40’ or 12m) straight beam into the machine just past the appropriate clamp/measuring disk.
• Manually close the appropriate clamp. With a metal square (or straight-edge) against a convenient flat surface on the machine
(or conveyor) use an awl to scribe a mark on the material.
• Type the following program in the MDI window:
G710
G0 G91 X ???
M0
M30
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…where ??? is the longest safe X axis move (in millimeters) before the trail end of material would pass out of the clamp/measuring
disk. This will be known as the “commanded distance”.
• Run MDI program. While the machine is stopped at the M0 block (before it executes the M30 block and unclamps) again scribe
a mark on the material identically to how it was done during the preparation step.
• Using the same certified measuring tape that is used to inspect finished parts, measure (in millimeters) the distance from
mark to mark and record this as the “actual distance”.
• Calculate the calibration value: (Orig. calibration val. × Actual Distance) ÷ Commanded Distance
• Enter the new calibration value into the appropriate scalefactor parameter. Perform an NCK Reset to apply change.
• Repeat as needed on either the entry or exit X axis measuring device.
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PCD 1100/3C ATC
13.2 Determine and Set X-axis Home Position
For the X-axis, the control automatically uses the drills’ location as the “0”, or home, position. When a program starts and the
machine finds the leading edge of the material, a value needs to be preset into the X-axis as its “current” position. This value is
the true dimension between the reference switch and the drills.
To determine and set the X-axis home position:
• Insert an appropriately sharpened drill bit into the Y spindle.
• Manually clamp a suitable piece of material and prepare it for X-axis referencing.
• Manually position the Y-axis spindle over the material as desired.
• Type the following program in the MDI window:
_XREF
M60
G4F5
M30
•
•
Run MDI program and wait for the M30 to execute.
Using the same certified measuring tape that is used to inspect finished parts, measure (in millimeters) the distance from the
leading edge of the material to the center of the mark produced by the punch. This is the X-axis home position.
To apply this change:
Enter the new Home Position value into the appropriate parameter noted above.
Perform an NCK Reset to apply change. Test and repeat as necessary.
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1: Safety
PCD 1100/3C ATC
13.3 Set Y/Z/W-axis Home Positions Using Absolute Measuring System
The Y, Z and W axes all use absolute measuring systems and therefore do not use a reference routine to find “home”. Essentially,
each axis always knows its position. If significant mechanical repairs are made to any of these axes it will be necessary to re-set
this known position. Use the instructions below to set the value. There are 2 control parameters that need to be set. They can be
found in: “Start-up/Machine Data/Axis MD”:
To set the home positions on all 3 axis:
1. Insert a drill bit in the desired spindle.
2. With all clamps open, place a straight edge along the machine’s passline (for Z and W axis, and use the datum line for Y
axis).
3. Jog the selected axis past the straightedge (approx. 6 in.) and measure up from the passline (or out from the datum for Y)
to the center point of the drill bit. For the most accurate measurement, it may also be necessary to extend the drill bit
closer by jogging the spindle feed.
4. Record and enter this value in Millimeters into parameter # 34100 as listed above.
5. Follow the below parameter change procedure starting with # 34210 and continue until it changes state (“1” to “2”):
a.
b.
c.
d.
e.
f.
g.
Use the Axis + / – keys to select the appropriate axis (Y, Z or W).
Scroll down to #34100
Set REFP_SET_POS[0] = Actual position of axis (mm or degrees)
Scroll down to #34210
Set ENC_REFP_STATE = 1
Put machine in “Jog” mode, press the “Ref Point” button and then press the “ Reset “ button.
Press and release the (- or +) button.
At this time the axis position should be preset to the value entered in REFP_SET_POS[0] and the ENC_REFP_STATE should change to
“2” as a confirmation.
13.4 Recover from a Program Interruption
At times it may become necessary to halt the execution of a part program after holes have been drilled but before the part
program has completed. Some program stops such as Cycle Stop or Safety Stop can be recovered from simply by clearing a message
and pressing the Cycle Start button. However, in the case of an Emergency Stop or certain program faults it will become necessary
to press the “Reset” button to clear the fault. The “Reset” button will cause the control to unclamp and the “current” block will
be reset to the beginning of the part program. In this case, there are various procedures to follow depending on which scenario
exists:
13.4.1 All the holes have been drilled
In this scenario, all the programmed holes have been drilled but the part program was halted before the final M30 command. This
leaves the “drill counters” at non-zero values. Before a new part program can be run, the “drill counters” need to be reset to
zero. This is done on the “Params/Misc” screen described earlier in this manual.
13.4.2 Some holes have been drilled, but not all
In this scenario, at least one hole has been drilled but the part program was halted before all of the holes have been drilled. If the
current part is to be completed the “drill counters” are already set properly and the part program need only be restarted from the
beginning. Previously drilled holes will be skipped automatically. If the current part is to be set aside for the moment and a new
part processed follow the instructions for “All the holes have been drilled”. When it’s time to complete the original part follow the
instructions for “Completing a partially processed part.”
13.4.3 Completing a partially processed part
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In this scenario, a part previously started yet not completed, needs to be restarted after the “drill counters” have been reset
either manually or by completing other part programs. First load and select the original part program. Next, individually count the
number of previously drilled holes on each drilling surface and enter these values into the respective “drill counters”. This is done
on the “Misc” screen described earlier in this manual. Last, press Cycle Start to start the program normally. Previously drilled holes
will be skipped automatically.
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13.5 Set Spindle Feed and RPM
13.5.1 Spindle Feed Axes
Spindle feed axes all have a “home” position set relative to the face of the spindle (not the key). For the Y spindle feed zero (0) is
the machine passline. For both Z & W spindle feeds zero (0) is the machine datum line. None of the spindle feed axes can
physically get to zero so their respective home positions are always a positive value measured from zero. When jogging these feed
axes (described later) or considering parameters that affect these feed axes negative (minus) motion is always towards zero(0) [or
towards the material] while positive (plus) motion is always away for zero [or away from material].
To set the home position of a spindle feed axis:
1. Jog the axes to a convenient location to measure from zero
2. Measure the distance from zero as accurately as possible in millimeters
3. Enter the measured distance (in .001mm) into DriveMD 2599 of the appropriate drive. (Example: 184.5mm is entered as
184500)
4. Change DriveMD 2507[0] to “2”. It will immediately set itself to “3” when it sets the measured/entered value into the
current axis position
5. Use “Save/Save – Drive System” in the DriveMD area to copy the new data to system ROM
6. Look at DriveMD 2521 to confirm the actual position has been set. Remember: It is displayed in .001 mm.
To adjust the soft limits of a spindle feed axis:
1. Enter minus soft limit (in .001 mm) in DriveMD 2580, enter plus soft limit (in .001 mm) in DriveMD 2581.
2. Use “Save/Save – Drive System” in the DriveMD area to copy the new data to system ROM
To jog a spindle feed axis:
1. Press and hold the MCP “Tool Mode” button for 4 seconds (until the “Manual Tool Mode” message is displayed.
2. Select “Auto” mode from among “Auto/MDA/JOG” on the MCP
3. Select the appropriate axis (Y/Z/W) using the normal axis selection buttons on the MCP
4. Use the normal jog (+) and (-) pushbuttons to jog the axis. Remember: “Minus” is towards the material and “Plus” is away
from material.
5. The normal feed rate override % knob on the MCP can be used to adjust the jog speed. The “Rapid” pushbutton has no
effect.
Caution
When you press the MCP “Tool Mode” button (to exit “Manual Tool Mode”) after
jogging a spindle axis the PLC will automatically command the axis back to a
safe retracted position. Do not exit “Manual Tool Mode” until you completed
whatever task you were jogging the axes for and the machine is clear of
obstructions.
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13.5.2 Spindle RPM Axes
Spindle RPM axes all have a reference switch used to establish home when orienting the spindle. The first orientation sequence
(after a machine power-on or NCK reset) will use the switch. Subsequent orientation sequences will “remember” the home position
and go there without first finding the switch. During a sequence that uses the switch, after finding the switch the axis optionally
rotates an additional amount (as determined via parameter). This additional amount will vary from machine to machine and
spindle to spindle and must be set properly to assure proper key orientation for a tool change.
To set the home position of a Spindle RPM axis:
1. Manually position the axis gage in line with one of the five tool change positions.
2. Manually position the spindle feed axis so tool groove is aligned with magazine tool holders.
3. Press and hold the MCP “Tool Mode” button for 4 seconds (until the “Manual Tool Mode” message is displayed. While in
“Manual Tool Mode” all orientation sequences will use the reference switch.
4. Select “MDA” mode from among “Auto/MDA/JOG” on the MCP
5. Enter appropriate orientation m-code in MDA window (Y:M69 - Z:M79 - W:M89)
6. Press Cycle Start (Spindle will find the reference switch and move the additional amount (per parameter).
7. Manually/slowly move the tool change magazine towards spindle. If the keys are not aligned continue to the next step.
8. Enter new value in DriveMD 2600 (in 0.1 degrees) – this is the additional amount of rotation the spindle travels after
finding the reference switch. (Example: 92.5 degrees is entered as 925)
9. Use “Save/Save – Drive System” in the DriveMD area to copy the new data to system ROM
10. Repeat steps 5-9 until keys align.
To jog a spindle RPM axis:
1. Press and hold the MCP “Tool Mode” button for 4 seconds (until the “Manual Tool Mode” message is displayed.
2. Select “MDA” mode from among “Auto/MDA/JOG” on the MCP
3. Select the appropriate axis (Y/Z/W) using the normal axis selection buttons on the MCP
4. Use the normal jog (+) and (-) pushbuttons to jog the axis.
5. The normal feed rate override % knob on the MCP can be used to adjust the jog speed. The “Rapid” pushbutton has no
effect.
To manually run a spindle at a specific RPM (without spindle feed):
1. Press and release the MCP “Tool Mode” button until “Auto Mode” is selected.
2. Select “MDA” mode from among “Auto/MDA/JOG” on the MCP
3. Enter appropriate S##=xxx code for the current spindle / tool number. (See tables) (Example: S11=1000 is entered to set Y
spindle tool #1 at 1000 rpm)
4. On the next MDA line enter appropriate m-code (Y: M96 – Z: M97 – W: M98)
5. Press Cycle Start
6. To stop press and hold MCP Reset button for 3+ seconds.
13.6 Motor Replacement
To replace a motor or drive component on an already running machine:
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1.
2.
3.
4.
5.
6.
7.
Power-Off at main disconnect.
Replace component.
Power-On at main disconnect.
Wait a minimum of 5 minutes to allow any/all firmware updates to occur (this will happen automatically).
Power-Off at main disconnect.
Power-On at main disconnect.
Slowly jog affected axis to prove motion then you’ll likely need to set a new axis “home” position.
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PCD 1100/3C ATC
13.7 Change the Voltage
In the event that a machine is sent to a new location and the incoming power supply is a different voltage and/or frequency there
are a number of drive parameters that need to be set-up:
•
•
•
•
P10 Infeed commissioning parameter filter. Setting to a value of “1” enables the following parameters to be modified.
p210 identifies the incoming line voltage (usually 480Vac in the US, 400Vac in Europe, etc…)
p211 is the frequency of the incoming line voltage (usually 50Hz or 60Hz). If p3409 = 1 (default) then p211 will be determined
and set automatically during infeed line detection described below.
p3410 controls the “Infeed Line Identification” Default setting is a 3, which means that the first time pulses are enabled in the
line module (when we come out of E-Stop), the Line Module will 'identify' the incoming 3 phase line. This will take 20-30
seconds and make a high-pitched noise. After the identification is completed successfully, p3410 will reset to 0.
Before the machine is powered off the last time and prepared for shipping at Peddinghaus, p210 should be set to the planned
destination voltage and p3410 should be set back to 3 so that this identification will take place at the your site.
Below is the sequence that must be followed to ensure the correct voltage is read and saved when it arrives at your site:
1.
2.
3.
4.
5.
6.
7.
Set p10 to a value of “1”.
Change p210 to correct voltage.
Change p11 to correct frequency.
Set p3410 to a value of “3”.
Change p10 back to “0”.
Hit the “screen- up” hard key ( up arrow in lower left corner of monitor ) to exit.
When the “screen-up” key has been hit, you should be prompted to save drive parameters . (If, for some reason you are not
asked to save, then find the “save/reset” soft key on the right. This will also ask you if you wish to save the drive system)
Select “yes”.
8. Select “save all”
The p3410 parameter will automatically change back to “0” after the initial voltage check at the customer is complete.
13.8 Set the Tool Changer Cycle
The spindle / tool changer logic is intelligent enough to know which tool is currently held in the spindle. If the tool change cycle is
run where the new desired tool is already in the spindle it will not put the tool away and re-acquire it.
The spindle / tool changer logic is also intelligent enough to know that if a tool has been manually removed from the spindle but
the “Current Tool” parameter has not been set to “0” and a new tool is request it does not need to return a tool to the magazine
first.
When a tool change cycle is run and a specific spindle does not need to do anything (either because it already has the correct tool
or “-1” is used) the spindle will still executed the first portion of the tool change sequence (orientation and move spindle feed to
“On Tool” position). This is by design in order to assure that the spindle and tool is physically out of the way of the other tool
changers.
Examples:
_TC(1,1,1) will cause all spindles to load tool #1
_TC(-1,4,0) will cause Z spindle to load tool #4, W spindle will unload its tool, Y spindle does nothing
_TC(0,0,0) will cause all spindles to return their tools to the magazine
To set the tool changer cycle:
The tool change cycle is a single cycle that affects all 3 spindles / tool changers. In “Auto” or “MDA” mode the syntax is the same.
_TC(y,z,w) where “y”, “z” or “w” is the new desired tool for each spindle. Allowed values for “y”, “z” & “w” are as follows:
-1
Do not change this spindle’s tool
0
Return current tool to magazine
1-5
Return current tool to magazine and get new desired tool (1-5)
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13.9 Tool Change Procedure
The PCD 1100/3C is equipped with a keyed perimeter guard fence with interlocked gates to prevent access to hazardous zones
during operation. The following is a description of how in-process tool changes are accomplished:
•
•
•
•
•
•
•
•
•
Press “Cycle Stop”
Press and hold “Tool Mode” button for 5 sec. to enter “Tool Manual Mode.” This causes the PLC to remove hydraulics from
everything except the tool changer gripper solenoids.
Turn Fortress Interlock key from “RUN” to “GATE ACCESS” position. After 3 seconds, the safety relay removes power from all
drives and dumps pneumatic pressure. The HPU pump remains on to power the tool changer gripper solenoids.
Enter the hazard zone (now in “safe” status) by removing Fortress Interlock key and using key to open perimeter gate.
Use the manual tool change knobs (Y, Z and X axes) to open respective grippers to accomplish tool changes, as needed. NOTE:
If drill tool length changes, the operator must manually reset the tool length to 0.0. If other tool type length changes, the
operator must manually enter the new length.
Exit the hazard zone and close the gate. Return to console, re-insert Fortress Interlock key and turn back to “RUN” position.
Press “Fault” button to clear errors and reset safety relay. This restores power to all drives, full hydraulic functionality and
pneumatic pressure.
Press “Tool Mode” button repeatedly until desired tool mode is selected (Off, Auto, Mark, Test).
Press “Cycle Start” to resume program.
Warning
Drill bits and drill chips have sharp edges. Wear protective gloves whenever
handling sharp objects to avoid injury.
13.10 Jog the Measuring Disk
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The measuring disk can be jogged up/down for testing only when both horizontal clamps are unclamped by entering Jog mode,
selecting the X axis, and using the normal “+” and “-“ jog buttons.
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14.0 Access Levels
There are three main password protected access levels in the Siemens 840Di control. They range from low to high: User, Service,
and Manufacturer. Certain screens and functions are hidden from lower access levels. In reality, there are four additional access
levels all lower than “User” that are determined by the keyswitch on the machine control panel. Peddinghaus has chosen not to
use these access levels. Anyone operating the machine should be at access level “User” as a minimum. The Siemens access level /
password concept and the softkey labels can be confusing and it is important for anyone with an access level higher than “User” to
understand the concepts and labeling of the access levels.
14.1 Determining Current Access Level
•
•
Enter the Start-Up operating area by pressing the “Menu Select” (Area Switchover) button, followed by the “Start-Up” softkey.
The current access level will appear near the bottom of the screen.
14.2 Raising the Access Level
•
•
•
•
•
Enter the Start-Up operating area by pressing the “Menu Select” (Area Switchover) button, followed by the “Start-Up” softkey.
Press the “Password…” softkey.
Press the “Set Password” softkey.
Enter the password for the higher access level using the alphanumeric keys.
Press the “Input” key.
14.3 Lowering the Access Level
Unlike raising the access level, you cannot directly lower the access level by simply entering the appropriate password. Instead,
the current password must be “deleted”, and a new one established:
•
•
•
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•
Enter the Start-Up operating area by pressing the “Menu Select” (Area Switchover) button, followed by the “Start-Up” softkey.
Press the “Password…” softkey.
Press the “Delete Password” softkey. The access level is now reduced to the keyswitch level, and will need to be raised for
machine operation.
Follow the instructions for raising the access level to establish the new password.
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14.4 Changing Passwords
The standard passwords are set by Siemens— Peddinghaus does not change them. If the machine owner decides to change the
passwords and subsequently loses the passwords, Peddinghaus will NOT be able to recover them without a paid visit by a service
technician. For this reason, Peddinghaus HIGHLY recommends keeping the verbally supplied password for access level “Service”
unchanged and strictly confidential. As a rule, Peddinghaus maintains the password for “Manufacturer” access level as private.
If it becomes necessary to change a password:
• Enter the Start-Up operating area by pressing the “Menu Select” (Area Switchover) button, followed by the “Start-Up” softkey.
• Press the “Password…” softkey.
• Press the “Change Password” softkey.
• On the newly displayed screen, select which access level’s password you wish to change. Only the current access level and
lower levels can be selected.
• Enter the new password using the alphanumeric buttons.
• Confirm the new password and press the “OK” softkey.
The default password for the “User” access level is CUSTOMER
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Chapter 14L
Chapter
Access
1: Safety
Levels
PCD 1100/3C ATC
15.0 Additional Installed Programs
In addition to the standard Siemens control software, Peddinghaus also makes available several other pieces of software that can
be used when necessary. Some of these applications may only be available at access levels higher than “User”.
15.1 Peddimat Programming System
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The Peddimat Programming System is used for the viewing/editing of parts and the creation of part programs. It can be accessed
by pressing the “Menu Select” button, followed by the “Peddimat” softkey. Peddimat can be used at any time, even during part
program execution. Peddimat contains it’s own built in help system and tutorials.
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15.2 Updating Peddimat
On occasion it may become necessary to update the version of Peddimat running on the Siemens control. This is accomplished by
placing the update diskette in the diskette drive, pressing the “Menu Select” button, followed by the “ETC” (>) button and finally
the “Peddimat Update” softkey. Follow the on-screen instructions until complete.
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Chapter 15: Additional Installed
Chapter Programs
1: Safety
PCD 1100/3C ATC
16.0 Code Listing
RPM & Feed rate during drilling, tapping & countersinking are set per tool via S & F codes. S codes are always in RPM while F codes
are dependent on the current mm (G710) vs. Inch (G700) mode.
Surface
Y (Web)
Z (Bottom Flange)
W (Top Flange)
Tool #
S Code
1
S11
2
S12
3
S13
4
S14
5
S15
1
S21
2
S22
3
S23
4
S24
5
S25
1
S31
2
S32
3
S33
4
S34
5
S35
Example (G700 active): S11=1200 F18.5 sets Y – Tool 1 to 1200 RPM and 18.5 in/min
Example (G710 active): S34=1440 F500 sets W – Tool 4 to 1440 RPM and 500 mm/min
Surface
Drill
Mark
Sink
Tap
Signo
Lube
Y (Web)
M61
M60
M64
M65
M66
M67
Z (BF)
M71
M70
M74
M75
M76
M77
W (TF)
M81
M80
M84
M85
M86
M87
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Double Drill (Tubing Only) on Y (Web)
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M161
PCD 1100/3C ATC
Signo Off (Retract
Web Probe
M16
Infeed
Outfeed
Start Probe Cycle
M9
M10
Enable Probe as Y Drill Clamp
M54
M56
Disable Probe as Y Drill Clamp
M55
M57
Close
Open
Infeed
M50
M51
Outfeed
M52
M53
Vertical and Horizontal Clamps
Disable Non-Datum Vertical Clamps
M59
Full Open
M20
Saw
Start
Crop
M49
M48
Signomat Stamp
M40
Z-axis Feed Full Retract
M23
Retract All Spindles
M99
Part Weight (Lb/ft)
H1
Section Depth (mm)
H2
Y-axis (Web) Countersink Depth (mm)
H3
Z-axis (BF) Countersink Depth (mm)
H4
W-axis (TF) Countersink Depth (mm)
H5
Section Height (mm)
H7
Saw Miter Angle (degrees)
H8
Section Web Thickness (mm)
H11
Section Flange Thickness (mm)
H12
Measuring Disk Height (mm)
H13
Entry Web Probe Value
$A_INA[1]
Exit Web Probe Value
$A_INA[2]
Last Web Probe Offset
R9
Y-axis (Web) Hole Counter
R11
Z-axis (BF) Hole Counter
R12
W-axis (TF) Hole Counter
R13
Traverse Mode
G00
Linear Interpolation Mode
G01
Inch Mode
G700
Metric Mode
G710
Absolute Mode
G90
Incremental Mode
G91
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PCD 1100/3C ATC
Stop Program Preprocessing
STOPRE
Tool Offset Active
G54
Tool Offset Inactive
G500
X-axis Acceleration Value (percent)
ACC[x]=%
Program Stop
M0
End of Program
M30
The following table contains additional M Codes not normally used in part programming, but which may be useful during machine
set-up.
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Description
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Y
Z
W
Tool Changer Magazine Extend
M18
M28
M38
Tool Changer Magazine Retract
M19
M29
M39
Tool Gripper—Grip
M11
M21
M31
Tool Gripper—Release
M12
M22
M32
Spindle Orient
M69
M79
M89
Spindle RPM Test
M96
M97
M98
Move Spindle Feed to “On Tool” position
M62
M72
M82
Move Spindle Feed to “Off Tool” position
M63
M73
M83
Purge Spindle Lubricant
M67
M77
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PCD 1100/3C ATC
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PCD 1100/3C ATC
17.0 Parameter Screen Program
17.1 Parameter Screen
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Having pressed the Menu Select button on the operator’s panel, the lower right hand corner will have a button labeled “Params”.
Press the “Params” button and the above screen will appear showing the parameter section for the machine.
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PCD 1100/3C ATC
17.1.1 Category
A pull down listing of all parameter sections for the machine will exist here. Selection of one of these categories will bring up the
parameters involved with a particular operational area of the machine.
17.1.2 Category Selected
Once a category has been selected, a number of parameters will appear with the parameter name, a value, and a particular action
required only for certain parameters after a parameter has been changed. The Value column will be editable for most of the
parameters but not all.
Note
Access to specific data in the Value column is controlled by password-protected access levels.
Some parameters will be “read only”, while others might be only changeable under
Manufacturing or Supervisor access levels. Parameters with the action “PO” will require a NCK
Reset.
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17.1.3 Saving Parameters
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Press the "Save to File" button located on the right side of the Operator’s Panel to backup a copy of the current machine
parameters. Once the button has been pressed the above “Save to File” dialog box will appear. Here you will be able enter in a
specific name and select a specific location for the saved parameters. The files are saved with an extension “.oldped”. You can
overwrite any existing files by typing in an existing file name.
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17.1.4 Loading Parameters
Press the “Load from File” button located on the right side of the Operator’s Panel to revert back to a previously saved set of
machine parameters. Once the button has been pressed the above “Load from File” dialog box will appear. Here you will be able
to select the specific file you want to load (only files with extension “.oldped” will appear).
You can delete parameter files here by pressing the right mouse button while highlighting a specific file. Next press “Delete” on
the pop-up menu.
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17.1.5 Convert
Press the “Convert” button located on the right side of the Operator’s Panel to have the above “Convert” dialog box appear. Here
you can quickly convert mm to inches or vice versa and perform simple math functions.
17.1.6 NCK Reset
Press the “NC Reset” button located on the right side of the Operator’s Panel to perform an NCK Reset of the control for those
parameters which require an action “PO”.
17.1.7 Refresh Values
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Press the “Refresh Values” button to see current values for those parameters that are automatically changed by the PLC.
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17.2 Monitor Screen
Pressing the button labeled “Monitor” will display the above screen.
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17.2.1 Load Monitor File
Press the “Load from File” button located on the right side of the Operator’s Panel to load any monitor file. The above “Load from
File” dialog box will appear. Here you can select the specific monitor file you want (only files with an extension “csv” will
appear).
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You can copy or delete monitor files by pressing the right mouse button while highlighting a specific file. Next press the desired
option. This is only available for those with access Service level and higher.
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17.2.2 Monitor File Format
Monitor files should have the extension “.csv” and are defined in the following manner:
Address,Description,DataType
Example 1 (“db86.csv”):
db86.dbb0.0,Analog Input Value,INT
db86.dbb2.0,Analog Output Value,INT
db86.dbb12.0,Actual Voltage Value,REAL
Example 2 (‘Inputs.csv”):
I2.0,CycleStop,X
I3.7,MCPReset,X
I4.6,MinusKey,X
I4.7,PlusKey,X
I5.6,JogPunchPB,X
I6.1,TorchRestartPB,X
I6.2,TorchLowPB,X
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17.3 Command Button Screen
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Press the button labeled “Command Buttons” and the above screen will appear showing the command button section.
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17.3.1 Load Command Button File
Press the “Load from File” button located on the right side of the Operator’s Panel to load any command button file. When
pressed the above “Load from File” dialog box will appear. Here you can select the specific command button file you want (only
those files with an extension “.cbt” will appear).
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You can copy or delete command button files by pressing the right mouse button while highlighting a specific file. Next press the
desired option. This is only available for those with access Service level and higher.
Command Button File Format
Command Button files should have the extension “.cbt”. Either 1 or 2 command buttons can be defined per line.
1 Command Button per line format:
Main Label, Button1 Label, Button1 command, ##
2 Command Buttons per line format:
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Main Label, Button1 Label, Button1 command, Button2 Label, Button2 command
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17.3.2 Command Button Example
“pinchdrives.cbt”:
Vertical Entry Clamp,CLOSE,M50,OPEN,M51
Vertical Exit Clamp,CLOSE,M56,OPEN,M57
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Appendix I: Peddinghaus Services
Peddinghaus Corporation
300 North Washington Avenue
Bradley, Illinois 60915 USA
(815) 937-3800 ◦ (800) 786-2448 (Toll Free)
(815) 937-4003 (Main Fax) ◦ (815) 937-4146 (Service Fax)
www.peddinghaus.com
Training, Service, and Support
The Service Technician provides a limited amount of training at the time of installation. Refer to
the sales quote for more information about the standard training. Different types of training are
provided, such as operator training, supervisor training, maintenance training and safety.
Additional training is also available from Peddinghaus.
For questions regarding training options, obtaining service for your machine, or if you have
questions regarding your machine, contact the Peddinghaus Service Department.
Peddinghaus Service Department
Peddinghaus Corporation’s Technical Support Specialists are available to assist our customers
across the world. Check www.peddinghaus.com for current call center hours.
Phone: (815) 937-3800, Extension 328
Fax: (815) 937-4146
Online Assistance and Request Forms:
http://www.Peddinghaus.com
http://www.Peddinghaus.com/ContactUs.asp
For questions regarding particular parts of your machine or spare parts, contact the Peddinghaus
Inside Sales / Parts Support Department.
Peddinghaus Inside Sales / Parts Support
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Phone: (815) 937-3800, Extension 259
Fax: (815) 937-4779
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Appendix II: Drill Speed & Feed Charts
CAT 40—Inch Sizes
Kennametal CAT 40 (Inch)
Decimal
Fraction
RPM
Allied CAT 40 (Inch)
IPM
Decimal
Fraction
PeddiTwist CAT 40 (Inch)
RPM
IPM
Decimal
Fraction
MT SIZE
RPM
IPM
0.500
1/2
2250
33.75
0.375
3/8
1800
10.80
0.375
3/8
3
713
5.0
0.547
35/64
2095
37.43
0.438
7/16
1659
9.95
0.438
7/16
3
611
4.9
0.563
9/16
2037
30.56
0.484
31/64
1498
8.99
0.484
31/64
3
552
4.9
0.625
5/8
1833
27.50
0.500
1/2
1451
8.71
0.500
1/2
3
535
4.9
0.672
43/64
1706
25.58
0.547
35/64
1327
13.27
0.547
35/64
3
489
4.8
0.688
11/16
1667
25.00
0.563
9/16
1290
12.90
0.563
9/16
3
475
4.8
0.750
3/4
1528
22.92
0.625
5/8
1161
11.61
0.625
5/8
3
428
4.7
0.813
13/16
1410
21.16
0.672
43/64
1080
10.80
0.672
43/64
3
398
4.6
0.875
7/8
1310
19.64
0.688
11/16
1056
10.56
0.688
11/16
3
389
4.6
0.891
57/64
1287
19.30
0.750
3/4
968
12.58
0.750
3/4
3
357
4.5
0.938
15/16
1222
18.33
0.813
13/16
893
11.61
0.813
13/16
3
329
4.5
1.000
1
1146
17.19
0.875
7/8
829
10.78
0.875
7/8
3
306
4.0
1.063
1 1/16
1079
16.18
0.891
57/64
815
10.59
0.891
57/64
3
300
4.4
1.125
1 1/8
1019
15.28
0.938
15/16
774
10.06
0.938
15/16
3
285
4.3
1.188
1 3/16
965
14.47
1.000
1
726
10.89
1.000
1
3
267
4.2
1.250
1 1/4
917
13.75
1.063
1 1/16
683
10.25
1.063
1 1/16
3
252
4.2
1.313
1 5/16
873
13.10
1.125
1 1/8
645
9.68
1.125
1 1/8
3
238
4.1
1.375
1 3/8
833
12.50
1.188
1 3/16
611
9.17
1.125
1 1/8
4
238
4.1
1.438
1 7/16
797
11.96
1.250
1 1/4
581
8.71
1.188
1 3/16
3
225
4.0
1.500
1 1/2
764
11.46
1.313
1 5/16
553
8.29
1.188
1 3/16
4
225
4.0
1.375
1 3/8
528
7.92
1.250
1 1/4
3
214
3.9
1.438
1 7/16
505
8.80
1.250
1 1/4
4
214
3.9
1.500
1 1/2
484
7.74
1.313
1 5/16
3
204
3.8
1.563
1 9/16
464
7.43
1.313
1 5/16
4
204
3.8
1.625
1 5/8
447
7.15
1.375
1 3/8
4
194
3.8
1.688
1 11/16
430
6.88
1.438
1 7/16
4
186
3.7
1.750
1 3/4
415
6.64
1.500
1 1/2
4
178
3.6
1.813
1 13/16
400
6.41
1.563
1 9/16
4
171
3.5
1.875
1 7/8
387
6.19
1.625
1 5/8
4
165
3.4
1.938
1 15/16
375
8.99
1.688
1 11/16
4
158
3.4
2.000
2
363
8.71
1.750
1 3/4
4
153
3.3
108
4
V1-R3
Appendix II: Drill Speed
Chapter
& Feed
1: Charts
Safety
PCD 1100/3C ATC
CAT 40—Metric Sizes
Kennametal CAT 40 (Metric)
Kennametal CAT 40 (Metric)
Allied CAT 40 (Metric)
RPM
mm/min
Size (mm)
RPM
mm/min
Size (mm)
RPM
12.5
1800
685.8
32.0
910
346.5
9.5
1800
274.32
13.0
1800
685.8
32.5
896
341.2
10.0
1800
13.5
1800
685.8
33.0
882
336.0
10.5
14.0
1800
685.8
33.5
869
331.0
11.0
14.5
1800
685.8
34.0
856
326.2
15.0
1800
685.8
34.5
844
15.5
1800
685.8
35.0
16.0
1800
685.8
35.5
16.5
1764
672.1
17.0
1712
17.5
18.0
V1-R3
Size (mm)
Allied CAT 40 (Metric)
RPM
mm/min
35.0
527
200.67
274.32
36.0
512
208.10
1756
267.56
37.0
498
202.47
1676
255.39
38.0
485
197.15
11.5
1603
244.29
39.0
473
192.09
321.4
12.0
1536
234.11
40.0
461
187.29
832
316.8
12.5
1475
224.75
820
312.4
13.0
1418
360.17
36.0
809
308.0
13.5
1365
346.83
652.3
36.5
797
303.8
14.0
1317
334.44
1663
633.7
37.0
787
299.7
14.5
1271
322.91
1617
616.1
37.5
776
295.7
15.0
1229
312.15
18.5
1573
599.4
38.0
766
291.8
15.5
1189
302.08
19.0
1532
583.7
38.5
756
288.0
16.0
1152
292.64
19.5
1493
568.7
39.0
746
284.3
16.5
1117
283.77
20.0
1455
554.5
39.5
737
280.7
17.0
1084
275.43
20.5
1420
541.0
40.0
728
277.2
17.5
1053
267.56
21.0
1386
528.1
18.0
1024
338.16
21.5
1354
515.8
18.5
996
329.02
22.0
1323
504.1
19.0
970
320.36
22.5
1294
492.9
19.5
945
312.15
23.0
1265
482.2
20.0
922
304.34
23.5
1239
471.9
20.5
899
296.92
24.0
1213
462.1
21.0
878
289.85
24.5
1188
452.6
21.5
857
283.11
25.0
1164
443.6
22.0
838
276.68
25.5
1141
434.9
22.5
819
270.53
26.0
1119
426.5
23.0
801
264.65
26.5
1098
418.5
24.0
768
253.62
27.0
1078
410.7
25.0
737
280.93
27.5
1058
403.3
26.0
709
270.13
28.0
1040
396.1
27.0
683
260.12
28.5
1021
389.1
28.0
658
250.83
29.0
1004
382.4
29.0
636
242.18
29.5
987
375.9
30.0
614
234.11
30.0
970
369.6
31.0
595
226.56
30.5
954
363.6
32.0
576
219.48
31.0
939
357.7
33.0
559
212.83
31.5
924
352.0
34.0
542
206.57
109
3
Visit us at www.Peddinghaus.com
mm/min Size (mm)
PCD 1100/3C ATC
CAT 40—Metric Sizes (continued)
PeddiTwist CAT 40 (Metric)
Size (mm)
RPM
10.0
679
127
10.5
647
11.0
11.5
PeddiTwist CAT 40 (Metric)
mm/min Size (mm)
RPM
mm/min
34.0
194
97
126
35.0
189
95
617
126
36.0
184
94
591
125
37.0
179
93
12.0
566
124
38.0
174
92
12.5
543
124
39.0
170
90
40.0
166
89
13.0
522
123
13.5
503
123
14.0
485
122
14.5
468
121
15.0
453
121
15.5
438
120
16.0
424
119
16.5
412
119
17.0
399
118
17.5
388
117
18.0
377
117
18.5
367
116
19.0
357
116
19.5
348
115
20.0
340
114
20.5
329
113
21.0
323
113
21.5
316
112
22.0
309
112
22.5
302
111
23.0
295
111
23.5
289
110
24.0
283
109
24.5
277
109
25.0
272
108
26.0
261
107
27.0
252
106
28.0
243
104
29.0
234
103
30.0
226
102
31.0
219
100
32.0
206
99
33.0
200
98
110
4
V1-R3
Appendix II: Drill Speed
Chapter
& Feed
1: Charts
Safety
PCD 1100/3C ATC
DV 40—Inch Sizes
Kennametal DV 40 (Inch)
Allied DV 40 (Inch)
PeddiTwist DV 40 (Inch)
Fraction
RPM
IPM
Decimal
Fraction
RPM
IPM
Decimal
Fraction
MT SIZE
RPM
IPM
0.500
1/2
2250
33.75
0.375
3/8
1800
10.80
0.375
3/8
3
713
5.0
0.547
35/64
2095
37.43
0.438
7/16
1659
9.95
0.438
7/16
3
611
4.9
0.563
9/16
2037
30.56
0.484
31/64
1498
8.99
0.484
31/64
3
552
4.9
V1-R3
Decimal
0.625
5/8
1833
27.50
0.500
1/2
1451
8.71
0.500
1/2
3
535
4.9
0.672
43/64
1706
25.58
0.547
35/64
1327
13.27
0.547
35/64
3
489
4.8
0.688
11/16
1667
25.00
0.563
9/16
1290
12.90
0.563
9/16
3
475
4.8
0.750
3/4
1528
22.92
0.625
5/8
1161
11.61
0.625
5/8
3
428
4.7
0.813
13/16
1410
21.16
0.672
43/64
1080
10.80
0.672
43/64
3
398
4.6
0.875
7/8
1310
19.64
0.688
11/16
1056
10.56
0.688
11/16
3
389
4.6
0.891
57/64
1287
19.30
0.750
3/4
968
12.58
0.750
3/4
3
357
4.5
0.938
15/16
1222
18.33
0.813
13/16
893
11.61
0.813
13/16
3
329
4.5
1.000
1
1146
17.19
0.875
7/8
829
10.78
0.875
7/8
3
306
4.0
1.063
1 1/16
1079
16.18
0.891
57/64
815
10.59
0.891
57/64
3
300
4.4
1.125
1 1/8
1019
15.28
0.938
15/16
774
10.06
0.938
15/16
3
285
4.3
1.188
1 3/16
965
14.47
1.000
1
726
10.89
1.000
1
3
267
4.2
1.250
1 1/4
917
13.75
1.063
1 1/16
683
10.25
1.063
1 1/16
3
252
4.2
1.313
1 5/16
873
13.10
1.125
1 1/8
645
9.68
1.125
1 1/8
3
238
4.1
1.375
1 3/8
833
12.50
1.188
1 3/16
611
9.17
1.125
1 1/8
4
238
4.1
1.438
1 7/16
797
11.96
1.250
1 1/4
581
8.71
1.188
1 3/16
3
225
4.0
1.500
1 1/2
764
11.46
1.313
1 5/16
553
8.29
1.188
1 3/16
4
225
4.0
1.375
1 3/8
528
7.92
1.250
1 1/4
3
214
3.9
1.438
1 7/16
505
8.80
1.250
1 1/4
4
214
3.9
1.500
1 1/2
484
7.74
1.313
1 5/16
3
204
3.8
1.563
1 9/16
464
7.43
1.313
1 5/16
4
204
3.8
1.625
1 5/8
447
7.15
1.375
1 3/8
4
194
3.8
1.688
1 11/16
430
6.88
1.438
1 7/16
4
186
3.7
1.750
1 3/4
415
6.64
1.500
1 1/2
4
178
3.6
1.813
1 13/16
400
6.41
1.563
1 9/16
4
171
3.5
1.875
1 7/8
387
6.19
1.625
1 5/8
4
165
3.4
1.938
1 15/16
375
8.99
1.688
1 11/16
4
158
3.4
2.000
2
363
8.71
1.750
1 3/4
4
153
3.3
111
3
Visit us at www.Peddinghaus.com
PCD 1100/3C ATC
DV 40—Metric Sizes
Kennametal DV 40 (Metric)
Size (mm)
RPM
12.5
1800
685.8
13.0
1800
13.5
14.0
Kennametal DV 40 (Metric)
mm/min Size (mm)
Allied DV 40 (Metric)
RPM
mm/min
Size (mm)
RPM
32.0
910
346.5
9.5
1800
274.32
685.8
32.5
896
341.2
10.0
1800
1800
685.8
33.0
882
336.0
10.5
1800
685.8
33.5
869
331.0
11.0
14.5
1800
685.8
34.0
856
326.2
15.0
1800
685.8
34.5
844
15.5
1800
685.8
35.0
16.0
1800
685.8
35.5
16.5
1764
672.1
17.0
1712
17.5
18.0
Allied DV 40 (Metric)
mm/min Size (mm)
RPM
mm/min
35.0
527
200.67
274.32
36.0
512
208.10
1756
267.56
37.0
498
202.47
1676
255.39
38.0
485
197.15
11.5
1603
244.29
39.0
473
192.09
321.4
12.0
1536
234.11
40.0
461
187.29
832
316.8
12.5
1475
224.75
820
312.4
13.0
1418
360.17
36.0
809
308.0
13.5
1365
346.83
652.3
36.5
797
303.8
14.0
1317
334.44
1663
633.7
37.0
787
299.7
14.5
1271
322.91
1617
616.1
37.5
776
295.7
15.0
1229
312.15
18.5
1573
599.4
38.0
766
291.8
15.5
1189
302.08
19.0
1532
583.7
38.5
756
288.0
16.0
1152
292.64
19.5
1493
568.7
39.0
746
284.3
16.5
1117
283.77
20.0
1455
554.5
39.5
737
280.7
17.0
1084
275.43
20.5
1420
541.0
40.0
728
277.2
17.5
1053
267.56
21.0
1386
528.1
18.0
1024
338.16
21.5
1354
515.8
18.5
996
329.02
22.0
1323
504.1
19.0
970
320.36
22.5
1294
492.9
19.5
945
312.15
23.0
1265
482.2
20.0
922
304.34
23.5
1239
471.9
20.5
899
296.92
24.0
1213
462.1
21.0
878
289.85
24.5
1188
452.6
21.5
857
283.11
25.0
1164
443.6
22.0
838
276.68
25.5
1141
434.9
22.5
819
270.53
26.0
1119
426.5
23.0
801
264.65
26.5
1098
418.5
24.0
768
253.62
27.0
1078
410.7
25.0
737
280.93
27.5
1058
403.3
26.0
709
270.13
28.0
1040
396.1
27.0
683
260.12
28.5
1021
389.1
28.0
658
250.83
29.0
1004
382.4
29.0
636
242.18
29.5
987
375.9
30.0
614
234.11
30.0
970
369.6
31.0
595
226.56
30.5
954
363.6
32.0
576
219.48
31.0
939
357.7
33.0
559
212.83
31.5
924
352.0
34.0
542
206.57
112
4
V1-R3
Appendix II: Drill Speed
Chapter
& Feed
1: Charts
Safety
PCD 1100/3C ATC
DV 40—Metric Sizes (continued)
PeddiTwist DV40 (Metric)
RPM
10.0
679
127
10.5
647
11.0
11.5
V1-R3
Size (mm)
PeddiTwist DV 40 (Metric)
mm/min Size (mm)
RPM
mm/min
34.0
194
97
126
35.0
189
95
617
126
36.0
184
94
591
125
37.0
179
93
12.0
566
124
38.0
174
92
12.5
543
124
39.0
170
90
40.0
166
89
13.0
522
123
13.5
503
123
14.0
485
122
14.5
468
121
15.0
453
121
15.5
438
120
16.0
424
119
16.5
412
119
17.0
399
118
17.5
388
117
18.0
377
117
18.5
367
116
19.0
357
116
19.5
348
115
20.0
340
114
20.5
329
113
21.0
323
113
21.5
316
112
22.0
309
112
22.5
302
111
23.0
295
111
23.5
289
110
24.0
283
109
24.5
277
109
25.0
272
108
26.0
261
107
27.0
252
106
28.0
243
104
29.0
234
103
30.0
226
102
31.0
219
100
32.0
206
99
33.0
200
98
113
3
Visit us at www.Peddinghaus.com
PCD 1100/3C ATC
114
4
V1-R3
Appendix II: Drill Speed
Chapter
& Feed
1: Charts
Safety