PFT BOARDMASTER 2500 Operating Manual
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PFT BOARDMASTER 2500 Operating Manual

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Contents
2021-03-22
Operating manual
PFT BOARDMASTER 2500 / 3150 / 4000
PFT BOARDMASTER 2500 mobile
Safety – Setting up and commissioning
Operation – Spare parts lists
Mobile sheet cutting table
Item number of operating manual: 00537040
Article number of parts list – machine BOARDMASTER 2500: 00631891
Article number of parts list – machine BOARDMASTER 3150: 00631892
Article number of parts list – machine BOARDMASTER 4000: 00631893
Article number of parts list – machine BOARDMASTER 2500 mobile: 00631894
Read the operating manual prior to beginning any work!

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Summary of Contents for PFT BOARDMASTER 2500

  • Page 1 Article number of parts list – machine BOARDMASTER 3150: 00631892 Article number of parts list – machine BOARDMASTER 4000: 00631893 Article number of parts list – machine BOARDMASTER 2500 mobile: 00631894 Read the operating manual prior to beginning any work!
  • Page 2 © Knauf PFT GmbH & Co. KG Postfach 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Tel.: +49 (0) 93 23/31-760 Fax: +49 (0) 0 93 23/31-770 Technical hotline: +49 9323 31-1818 info@pft.net www.pft.net 2021-03-22...

  • Page 3: Table Of Contents

    10 Pneumatic power unit lifting system ..15 25 Electrotechnical equipment ...... 34 11 Workpiece ........... 15 25.1 Brake magnets ........34 11.1 BOARDMASTER 2500 ...... 15 11.2 BOARDMASTER 2500 mobile ..16 26 Pneumatic power unit lifting system ..35 11.3 BOARDMASTER 3150 ...... 16 2021-03-22...
  • Page 4 Safety – Setting up and commissioning Operation – Spare parts lists Contents 33 Spare parts list ........... 42 26.1 The pneumatic power unit lifting system on the back of the machine head......35 34 Accessories ..........45 26.2 Setting the lifting and lowering 34.1 Article number 00207783 speeds of the power units ....

  • Page 5: Ec Declaration Of Conformity

    Agent responsible for putting together the relevant technical documentation: Dipl.-Wirtsch.-Ing. Michael Duelli, Einersheimer Straße 53, 97346 Iphofen, Germany. The technical documentation is held at: Knauf PFT GmbH & Co.KG, Technische Abteilung, Einersheimer Straße 53, 97346 Iphofen, Germany. Iphofen, November 2015 Dr. York Falkenberg...

  • Page 6: General Information

    Congratulations on purchasing this mobile sheet cutting table; its design is geared towards adding efficiency and convenience to your daily work. It was developed by experts and for experts. You are thus the owner of a PFT brand-name product that will give you many years of service.

  • Page 7: Safety Symbols In This Manual

    Safety – Setting up and commissioning – Operation – Spare parts lists Safety symbols in this manual 3 Safety symbols in this manual The safety symbols along with the text of the safety message are to draw attention to unavoidable residual dangers involved in using the machine.

  • Page 8: Basic Safety Instructions

    Safety – Setting up and commissioning – Operation – Spare parts lists Basic safety instructions 4 Basic safety instructions 4.1 In case of emergency In case of dangerous situations at the machine (e.g., danger caused by unexpected  malfunctions), the system must be immediately shut down. Danger! The machine can be immediately shut down (mains disconnect) using EMERGENCY ...
  • Page 9 Safety – Setting up and commissioning – Operation – Spare parts lists Basic safety instructions USE A BREATHING MASK IN CASE OF WORK THAT CAUSES DUST AND CHIPS!  ALWAYS USE HEARING PROTECTION!  Secure the workpiece.  Attention! Before changing the units, the main switch must be switched to position ...

  • Page 10: Observing The Operating Instructions

    Follow the maintenance instructions and instructions for changing tools. Check the plug and the cable regularly and call in PFT customer service to replace them in case of damage. Check the extension cable regularly and replace it in the event of damage.

  • Page 11: Basic Safety Measures For Normal Operation

    Safety – Setting up and commissioning – Operation – Spare parts lists Basic safety instructions 4.4 Basic safety measures for normal operation During operation of the machine, no safety devices may be removed or disconnected.  Before each use, the operating personnel must make sure there are no unauthorised ...

  • Page 12: Special Safety Instructions For Operation

    Safety – Setting up and commissioning – Operation – Spare parts lists Special safety instructions for operation 5 Special safety instructions for operation Warning of cutting injuries! Warning of hand injuries! Safety goggles: To protect your the eyes against flying parts and liquid splashes. Ear protectors: To protect against hearing loss When working on the electrical equipment:...

  • Page 13: Technical Data Boardmaster

    Width 1620 Height 1380 Weight: Specification Value Unit Net weight BOARDMASTER Weight cutting table Weight machine head 6.2 BOARDMASTER 2500 mobile basic machine Article number 00631894 Dimensions of the working Specification Value Unit machine: Length 3010 Width 1620 Height 1380...

  • Page 14: Boardmaster 4000 Basic Machine Article Number 00631893

    3000 Fuse The on-site mains connection (socket) must be fused with 16 Ampere and have a fault current circuit breaker with 30 mA. (suitable adapters are available from PFT) Working electrical outlet Yes (1*) Comment (1*) The external total connected load to the mains socket is: Max.

  • Page 15: Positioning Laser (Optional)

    5 bar. The compressor used must be capable of building up at least 7 bar pressure. The hose must withstand a pressure of at least 10 bar (must be certified). (suitable compressors and pressure hoses are available from PFT) 11 Workpiece...

  • Page 16: Boardmaster 2500 Mobile

    Safety – Setting up and commissioning – Operation – Spare parts lists Workpiece 11.2 BOARDMASTER 2500 mobile Maximum operational load 150 kg Maximum board size 2500 mm x 1260 mm Maximum plate thickness 2500 mm x 1260 mm 48 mm 11.3 BOARDMASTER 3150...

  • Page 17: Proper Use Of The Machine

    Safety – Setting up and commissioning – Operation – Spare parts lists Proper use of the machine 12 Proper use of the machine Cutting of gypsum boards, gypsum fibre, cement fibre and hard plasterboard, fibreboard, chipboard, soft fibreboards. Production of moulded parts by means of V groove milling in all above mentioned materials. WARNING! Danger! Use only dry plates.

  • Page 18: Extraction Unit

    Safety – Setting up and commissioning – Operation – Spare parts lists Extraction unit 14 Extraction unit The mobile sheet cutting table is equipped with a suction hose. This is designed for extraction for both machine power units. There is no need to switch over between the power units.

  • Page 19: Machine Structure

    Safety – Setting up and commissioning – Operation – Spare parts lists Machine structure 15 Machine structure The machine consists of 4 assemblies: Assembly 4: Assembly 2: Assembly 3: Saw unit Machine head Milling cutting unit Assembly 1: Machine table 15.1 Direction of movement The direction of movement is divided into longitudinal (X) and transverse (Y) Control handle for...

  • Page 20: Direction Of Work

    Safety – Setting up and commissioning – Operation – Spare parts lists Machine structure 15.2 Direction of work Work to the left or right as per the working direction (red arrow) marked on the selected power unit mount. 15.2.1 Milling Direction of movement in operations Fig.

  • Page 21: Lever For Clamping

    Safety – Setting up and commissioning – Operation – Spare parts lists Lever for clamping 15.2.4 Milling with the groove saw – longitudinal Direction of movement during operation Use the unit on the left and right side Always note the direction of operation (red arrow on unit) Fig.

  • Page 22: Assemblies 3 And 4 Milling Cutter And Sawing Power Units

    Safety – Setting up and commissioning – Operation – Spare parts lists Overview of machine head 17.1 Assemblies 3 and 4 Milling cutter and sawing power units Use only original PFT power units. Fig. 15.03N Sixfold Saw Fig. 15.03 Cross Fig.

  • Page 23: Start-Up

    Safety – Setting up and commissioning – Operation – Spare parts lists Start-up All three units have 2 long slots [2] in their mounting plates on the underside as well as integrated electric connectors and an extraction opening (15.06). Ratchet lever (2) Electrical connector (3) Extraction connection (4) Positioning pin (1)

  • Page 24: Tool Change

    Safety – Setting up and commissioning – Operation – Spare parts lists Tool change 19 Tool change 19.1 Milling cutter unit To change the units, the main switch must be turned to position "0" OFF. Pull out the mains plug. An unintentional start of the units is thus prevented.

  • Page 25: Sawing Unit Sixfold

    Safety – Setting up and commissioning – Operation – Spare parts lists Tool change 19.3 Sawing unit sixfold To change the units, the main switch must be turned to position "0" OFF. Pull out the mains plug. An unintentional start of the units is thus prevented. Attention! •...

  • Page 26: Use A V Groove Saw Blade (Without Modification As Of Models 07.2013)

    Safety – Setting up and commissioning – Operation – Spare parts lists Tool change Changing the cutting tool (saw blade) is identical to the process for the longitudinal or cross-cut saw. Assembly is in reverse order. WARNING! When fitting the saw blade note the direction indicator on the groove sawing unit and on the blade .
  • Page 27 Safety – Setting up and commissioning – Operation – Spare parts lists Tool change When fitting the saw blade note the direction indicator on the groove sawing unit and on the blade (Fig. 18.06) Important!  Before using the groove cutting saw, set the depth gauge to 0 mm (Fig. 19.04). ...

  • Page 28: Other Documents

    Safety – Setting up and commissioning – Operation – Spare parts lists Other documents 20 Other documents In addition to this manual, observe the following documents:  IVO Magnetic length measuring system.  IVO Position display series.  Power unit operating instructions angle grinder. ...

  • Page 29: Troubleshooting/Fault Elimination

    Safety – Setting up and commissioning – Operation – Spare parts lists Troubleshooting / fault elimination 22 Troubleshooting / fault elimination Observe the safety instructions! This work must only be carried out by appropriately trained personnel! In case of overload or a fault occurring, The main and emergency stop switches can one of the fuses, F1 to F4, at the junction only be turned on if 230 V voltage is available...

  • Page 30: Speed Preselection For Milling Cutter, Sawing And Groove Sawing Power Unit

    Safety – Setting up and commissioning – Operation – Spare parts lists Speed preselection for milling cutter, sawing and groove sawing power unit Ratchet lever Machine head mounting plate with plug-in connection for milling cutter and sawing unit Electrical connector Extraction unit connector Positioning bolt 24 Speed preselection for milling cutter, sawing and groove...
  • Page 31 Safety – Setting up and commissioning – Operation – Spare parts lists Speed preselection for milling cutter, sawing and groove sawing power unit Speed preselection for milling cutter units 1530-Watt sawing unit, 1530-Watt sawing unit, 1600-Watt sixfold sawing unit, longitudinal cross-cutting longitudinal cutting Before installing any power unit, the power unit selection switch on the control panel must...

  • Page 32: Machine And Brake Control Panel

    Safety – Setting up and commissioning – Operation – Spare parts lists Speed preselection for milling cutter, sawing and groove sawing power unit 24.1 Machine and brake control panel Power unit selection X axis position Lock button for brake in Y Lock button for brake in X switch L –...

  • Page 33: Operation Longitudinal And Cross-Cut Axes - Position Displays

    Safety – Setting up and commissioning – Operation – Spare parts lists Speed preselection for milling cutter, sawing and groove sawing power unit To be able to switch off the machine quickly in an emergency situation, there is a yellow and red MAIN SWITCH (emergency stop switch) on the side of the control panel;...

  • Page 34: Electrotechnical Equipment

    Safety – Setting up and commissioning – Operation – Spare parts lists Electrotechnical equipment 25 Electrotechnical equipment 25.1 Brake magnets After setting the desired position in X or Y direction, you can use the lock key on the control panel to activate the brake for the X or Y direction.

  • Page 35: Pneumatic Power Unit Lifting System

    Safety – Setting up and commissioning – Operation – Spare parts lists Pneumatic power unit lifting system 26 Pneumatic power unit lifting system The automatic pneumatic lifting and lowering system makes it easy to lower the power units to the sheet to be cut.

  • Page 36: Setting The Lifting And Lowering Speeds Of The Power Units

    Safety – Setting up and commissioning – Operation – Spare parts lists Positioning laser (optional) Important! Before lowering the power units (milling cutter and sawing units), it is essential to ensure that the workpiece is clamped and your hands are not in the lowering path of the power units.
  • Page 37 Safety – Setting up and commissioning – Operation – Spare parts lists Positioning laser (optional) Tool centre point (2). Locking screw Right transverse laser Left transverse laser Right longitudinal Left longitudinal laser laser NOTE! The basic set-up of all lasers should be performed by a qualified technician. Never look directly into the laser beam, and only switch the laser on when it is needed as a positioning aid.
  • Page 38 Safety – Setting up and commissioning – Operation – Spare parts lists Positioning laser (optional) The following notes are from the the laser manufacturer's operating instructions. Operating and safety instructions for the operation of diode laser modules Please read the following instructions carefully and keep them in a safe place. ...

  • Page 39: Maintenance And Care

    Safety – Setting up and commissioning – Operation – Spare parts lists Maintenance and care 28 Maintenance and care All maintenance and repair work must be performed only when the main switch is turned off and the mains plug disconnected. To increase the service life and precision, we recommend cleaning the stops and guide surfaces daily to remove dust and dirt.

  • Page 40: Storage And Transport Conditions

    Safety – Setting up and commissioning – Operation – Spare parts lists Storage and transport conditions 30 Storage and transport conditions • The machine head and the associated power units must be stored in the crate provided for this purpose during transport. •...

  • Page 41: Checklist - Please Tick

    Safety – Setting up and commissioning – Operation – Spare parts lists Checklist – please tick 32 Checklist – please tick 1. Setting up the machine head The two front latches on the machine head have been correctly closed: The two rear latches on the machine head have been correctly closed: Neither the magnetic belt nor magnetic mounts were damaged (visual inspection): The machine head’s running properties were checked for ease of movement: 2.

  • Page 42: Spare Parts List

    Safety – Setting up and commissioning – Operation – Spare parts lists Spare parts list 33 Spare parts list Item Fig. Item no. Designation 00208159 Housing for milling cutter unit 1400 Watts (BM) 00231377 Carbon brush milling cutter motor 1400 W CW/CCW (BM) Carbon brush milling cutter motor 1400 W 120 V 00208163 CW/CCW (BM)
  • Page 43 Safety – Setting up and commissioning – Operation – Spare parts lists Spare parts list 00208222 Saw housing 5x longitudinal universal (BM) 00208223 Saw housing 5x cross-cutting universal (BM) 00208234 Saw motor L/CC/5x universal (BM) 00231420 Carbon brush saw motor 1450W 230 V CW/CCW (BM) 00208237 Saw motor L/CC/5x universal 120 V (BM) 00208241...
  • Page 44 Safety – Setting up and commissioning – Operation – Spare parts lists Spare parts list 00208272 Extraction hose incl. adapter Dm: 38 mm/3 m (BM) 00208274 Extraction hose Dm: 38 mm/2.3 m (BM) 00208286 Skid plate 1400/1800 W soffit milling cutter inside (BM) 00208085 Table base plates in chip 8 mm (BM) 00208086...

  • Page 45: Accessories

    Safety – Setting up and commissioning – Operation – Spare parts lists Accessories 00231451 Stop set for cross-cut axis L + R (BM) 00231452 Locking lever for stops, front (BM) 00208325 Locking screws with slot nuts (BM) 00231459 Fuse set for switch box 4 pcs. (BM) 00208346 PFTfix nozzle attachment straight (BM) 00208347...

  • Page 46: Article Number 00206494 Boardmaster Tool Set Small

    Safety – Setting up and commissioning – Operation – Spare parts lists Accessories 34.2 Article number 00206494 BOARDMASTER tool set small Includes: Art. no. 00207792, 00207793, 00207795, 00207789, 00207796, 00207797, 00207799, 00207784, 00207800, 00207790, 00207801 00207792 Milling cutter set case empty (BM) 00207793 Copying and cutting end mill 7 mm (BM) 00207795...

  • Page 47: Article Number 00206422 Boardmaster Tool Set Fully Equipped No.: 46175

    Safety – Setting up and commissioning – Operation – Spare parts lists Accessories 34.3 Article number 00206422 BOARDMASTER tool set fully equipped No.: 46175 Includes: Art. no. 00207792, 00207793, 00207795, 00207789, 00207796, 00207797, 00207799, 00207784, 00207790, 00207800, 00207801. The following parts are included in the small tool set. 00207786, 00207802, 00207807, 00207808, 00207809, 00207810, 00207812, 00207788.
  • Page 48 Safety – Setting up and commissioning – Operation – Spare parts lists Accessories 1050-Watt milling device with an integrated suction 00207824 channel, 120 Volt Sawing device 1530-Watt for longitudinal sections with an 00207826 integrated suction channel, 230 Volt, Cut depth 48 mm Sawing device 1530-Watt for longitudinal sections with an 00207827 integrated suction channel, 120 Volt, Cut depth 48 mm...
  • Page 49 Safety – Setting up and commissioning – Operation – Spare parts lists Accessories 00207835 Vac control box for 120 Volt systems BOARDMASTER 00207836 Industrial suction system 50 l complete, 120 Volt 00207839 PFTfix priming device (BM) 00207840 PFTfix adhesive gun TEC 6100 230 V (BM) 00207841 PFTfix adhesive gun TEC 6100 120V (BM) 00207842...
  • Page 50 Safety – Setting up and commissioning – Operation – Spare parts lists Accessories 00207849 PFTset positioning carriage (BM) 00207850 PFTset groove template (BM) 00207852 Skid plate jamb router outside (BM) 00207854 PFTroll 310 insulating tape dispenser (BM) 00207856 PFTfix adhesive gun TEC 3200 (BM) 00207858 PFTfix special compressor (BM) No image...

  • Page 51: Tools

    Safety – Setting up and commissioning – Operation – Spare parts lists Tools 35 Tools Fig. Item no. Designation 00207790 Saw blade 160 mm (BM) 00207865 Saw blade 160 mm (BM) 00207866 Saw blade 120 mm (BM) 00207868 Saw blade 100 mm (BM) 00207869 Saw blade set 120 mm (6 pcs.) (BM) 00207871...
  • Page 52 Safety – Setting up and commissioning – Operation – Spare parts lists Tools Groove saw blade for aluminium composite materials 00207890 (BM) 00207891 PFTrev – revision hinge router 5.5 mm (BM) 00207793 Copying and cutting end mill 7 mm (BM) 00207895 End mill 8 mm for wood PKD coated (BM) V groove milling cutter 30°, plate thickness...
  • Page 53 Safety – Setting up and commissioning – Operation – Spare parts lists Tools 00207997 PFTstrong round edge cutter Dm 4.3 mm (BM) 00207998 PFTstrong round edge cutter Dm 5 mm (BM) 00207999 PFTstrong round edge cutter Dm 8 mm (BM) 00208000 PFTstrong round edge cutter Dm 10 mm (BM) 00208002...

  • Page 54: Consumables

    Consumables 36 Consumables Fig. Item no. Designation 00588821 PFT assembly spray 100 ml 00208069 PFTstrong flat bar edge stainless steel 1.5 x 9.5 mm 3x 00208071 PFTstrong perspex rod 4 mm/2 m (BM) 00208075 PFTstrong perspex rod 8 mm/2 m (BM)
  • Page 55 Safety – Setting up and commissioning – Operation – Spare parts lists 2021-03-22...
  • Page 56 PFT - ALWAYS AT YOUR SITE Knauf PFT GmbH & Co. KG Postfach 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Tel: +49 9323 31-760 Fax: +49 9323 31-770 Technical hotline: +49 9323 31-1818 info@pft.net www.pft.net...

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