PFT BOARDMASTER 2500 User manual

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: [phone]
Read the operating manual prior to beginning any work!

2 2021-03-22
© Knauf PFT GmbH & Co. KG
Postfach 60 97343 Iphofen
Einersheimer Straße 53 97346 Iphofen
Germany
Tel.: [phone]
Fax: [phone]
Technical hotline: [phone]
[email protected]
www.pft.net

Safety – Setting up and commissioning – Operation – Spare parts lists
Contents
2021-03-22 3
1EC Declaration of Conformity..................... 5
2General information..................................... 6
2.1 Information regarding the operating
manual ................................................. 6
2.2 Information on the safety
instructions........................................... 6
2.3 Symbols ............................................... 6
3Safety symbols in this manual ................... 7
4Basic safety instructions ............................ 8
4.1 In case of emergency .......................... 8
4.2 Basic safety instructions ...................... 8
4.3 Observing the operating instructions . 10
4.4 Basic safety measures for normal
operation............................................ 11
4.5 Basic safety measures during
maintenance ...................................... 11
5Special safety instructions for operation 12
6Technical data BOARDMASTER .............. 13
6.1 BOARDMASTER 2500 basic
machine Article number 00631891.... 13
6.2BOARDMASTER 2500 mobile basic
machine Article number 00631894.... 13
6.3 BOARDMASTER 3150 basic
machine Article number 00631892.... 13
6.4 BOARDMASTER 4000 basic
machine Article number 00631893.... 14
6.5 Electrical connection values .............. 14
7Positioning laser (optional) ...................... 15
8Operating conditions................................. 15
9Sound power level LWA............................ 15
10 Pneumatic power unit lifting system ....... 15
11 Workpiece................................................... 15
11.1 BOARDMASTER 2500...................... 15
11.2 BOARDMASTER 2500 mobile .......... 16
11.3 BOARDMASTER 3150...................... 16
11.4 BOARDMASTER 4000 ......................16
12 Proper use of the machine ........................17
13 Set-up location............................................17
14 Extraction unit ............................................18
15 Machine structure ......................................19
15.1 Direction of movement .......................19
15.2 Direction of work ................................20
16 Lever for clamping .....................................21
17 Overview of machine head ........................21
17.1 Assemblies 3 and 4 Milling cutter
and sawing power units......................22
18 Start-up........................................................23
19 Tool change ................................................24
19.1 Milling cutter unit ................................24
19.2 Saw unit..............................................24
19.3 Sawing unit sixfold .............................25
19.4 Groove sawing unit sixfold .................25
19.5 Use a V groove saw blade (without
modification as of models 07.2013) ...26
20 Other documents........................................28
21 Control elements ........................................28
21.1 Main switch and working sockets.......28
22 Troubleshooting/fault elimination ............29
23 Power unit connection device...................29
24 Speed preselection for milling cutter,
sawing and groove sawing power unit ....30
24.1 Machine and brake control panel.......32
24.2 Operation longitudinal and cross-cut
axes – position displays .....................33
25 Electrotechnical equipment ......................34
25.1 Brake magnets ...................................34
26 Pneumatic power unit lifting system........35

Safety – Setting up and commissioning Operation – Spare parts lists
Contents
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26.1 The pneumatic power unit lifting
system on the back
of the machine head. ......................... 35
26.2 Setting the lifting and lowering
speeds of the power units .................. 36
27 Positioning laser (optional)....................... 36
28 Maintenance and care................................ 39
29 Warranty provisions .................................. 39
30 Storage and transport conditions ............ 40
31 Disposal of the machine............................ 40
32 Checklist – please tick............................... 41
33 Spare parts list........................................... 42
34 Accessories................................................ 45
34.1 Article number 00207783
BOARDMASTER milling cutter new:. 45
34.2 Article number 00206494
BOARDMASTER tool set small......... 46
34.3 Article number 00206422
BOARDMASTER tool set fully
equipped No.: 46175 ......................... 47
35 Tools ........................................................... 51
36 Consumables ............................................. 54

Safety – Setting up and commissioning – Operation – Spare parts lists
EC Declaration of Conformity
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1 EC Declaration of Conformity
Company: Knauf PFT GmbH & Co. KG
Postfach 60
97343 Iphofen
Germany
declares, with exclusive responsibility, that the machine
Device type: Transportable sheet cutting table
Machine model: PFT BOARDMASTER 2500 / 3150 / 4000 / 2500 mobile
Serial number: See type plate
Guaranteed sound power level: 99dB(A)
described in the enclosed documentation is in accordance with the EC Machinery Directives
2006/42/EC, 93/68/EEC, 2004/108/ EEC, 2000/14/EC.
Furthermore, the following standards and regulations apply:
DIN EN 418 EN 1088
DIN EN 953 EN ISO 12100
DIN EN 349 EN ISO 13857/2008
DIN EN 954-1 EN 60204-1/97
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
General Manager
Place and date of issue Name and signature Information on undersigned

Safety – Setting up and commissioning – Operation – Spare parts lists
General information
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2 General information
2.1 Information regarding the operating manual
This manual provides important information and instructions on the correct use
of the equipment. Adherence to all defined safety and handling instructions is
a prerequisite for a safe working environment.
Additionally, the on-site accident prevention regulations and general safety
guidelines for the equipment must be followed at all times.
Read the manual carefully before starting any work! It is an integral part of
the product and must be kept near the machine and accessible to operators at
all times.
Always include the operating manual when transferring the machine to third
parties.
The diagrams and illustrations shown in the manual are intended for better
understanding of tasks and descriptions. They are not necessarily shown to the
correct scale and may vary slightly from the actual equipment used.
2.2 Information on the safety instructions
These safety instructions give important notes and instructions on the correct use
of the equipment. Adherence to all defined safety and handling instructions is
a prerequisite for a safe working environment.
2.3 Symbols
Warning symbols Warnings are shown by symbols in this manual. The warnings themselves open
with signal words that express the seriousness of the danger.
Adhere to these warnings at all times to avoid accidents, personal injury and
equipment damage.
DANGER!
... Indicates an immediate dangerous situation that will lead to death
or serious injury if it is not avoided.
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.

Safety – Setting up and commissioning – Operation – Spare parts lists
Safety symbols in this manual
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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. These residual risks relate to persons, the machine, other objects,
and the environment.
The following safety symbols are used in the present operating instructions.
Danger!
This symbol indicates a danger exists, above all to the life and health
of persons – in addition, it can point to potential risks for the machine,
objects or the environment.
If these instructions are not followed, this can lead to serious and even fatal injuries.
WARNING!
This symbol indicates that risks exist, above all for the machine,
objects and the environment – risks for persons are not expected.
If these instructions are not observed, this can lead to malfunctions and damage
to the machine. Damage to property and environmental damage can also occur.
This symbol indicates that, above all, health risks exist.
These risks emanate from on sharp, cutting and rotating tools.
This symbol indicates that, above all, health risks exist.
These risks emanate from moving parts that can cause trapping or crushing.
This symbol indicates specific risks to the health and life of persons
due to electric voltages.
Information!
This symbol indicates instructions that contribute to a better understanding
of the machine – the information will help you use the machine in the best
possible way. This symbol does not point to safety information.
Please also note that a safety symbol can never replace the wording of a safety
instruction – the wording of a safety instruction must therefore always be
read completely.

Safety – Setting up and commissioning – Operation – Spare parts lists
Basic safety instructions
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4 Basic safety instructions
4.1 In case of emergency
Danger!

In case of dangerous situations at the machine (e.g., danger caused by unexpected
malfunctions), the system must be immediately shut down.

The machine can be immediately shut down (mains disconnect) using EMERGENCY
STOP main switch on the control panel, or by disconnecting from the mains
supply (unplugging). The power supply is switched off immediately.

In case of accident notify the doctor and the Trading Standards Office, or appropriate
local authority.

Especially in case of high-voltage accidents, first aid must be given immediately
by appropriately trained persons.
4.2 Basic safety instructions

Do not misuse the machine. The mobile sheet cutting table must only be used for
the intended purpose.

Keep your machine and its accessories in good working order. A neglected machine
or neglected accessories pose dangers.

Regularly check your machine and its accessories for damage. Make sure that
moving parts and safety components are working correctly and not jammed;
check for damage to parts.

Take environmental factors into account. Never expose power tools to moisture.
Never use power tools near flammable liquids or gases.

Protect yourself against electric shock.

Keep children away. The mobile sheet cutting table and its accessories are not toys.
Make sure that children do not touch the tool or cable.

Wear suitable work clothes. Do not wear loose clothing or jewellery, they can be
dragged in by moving parts. Wear a hairnet if you have long hair.

MAKE SURE THERE IS SUFFICIENT LIGHTING OF THE WORK AREA!

USE PROTECTIVE EYEWEAR!

ALWAYS USE AN EXTRACTION UNIT FOR A SAFE AND DUST-FREE WORK!

Safety – Setting up and commissioning – Operation – Spare parts lists
Basic safety instructions
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
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
"0". Pay attention to the stoppage of the unit.

Pay attention to stable position so that you can k
eep your balance in any
working position.

Avoid unintentional switching on. Make sure that the main switch is switched off when
connecting to the mains power supply.

Be attentive at all times. Concentrate on your work. Take a sensible approach. Do not
use the machine if you are tired.

This machine may only be operated persons who are regarded as suitable for the
task by the plant manager or supervisor.

All persons who carry out work on the machine, must read the operating instructions
and confirm that they have understood the operating instructions by their signature.

When transporting individual components, at least two persons are required for parts
that are heavier than 25 kg (see technical data). (25 kg per person).

Switch off the machine and wait until the tool has reached idle position before leaving
the workplace. When not in use, before servicing, and when changing the tool,
additionally unplug the mains plug. Lock the main switch against unintentional
switching on.

Never touch the power units while the machine is running. Never lift power units by
their tools (saw blades or cutters); never reach under these tools. If you do need to
work on the power units (e.g., height adjustment of the sawing or milling cutting units)
turn off the machine at the main switch, and disconnect the machine from the mains
by unplugging the mains plug. During normal operations, only use the power unit
pneumatic lifting system to raise and lower the power units.

Never leave tool spanners in place. Before switching on, check whether the spanners
and adjusting tools have been removed.

Use the right tools. Intended use is described in this manual. With the right tools, you
will achieve optimum quality and ensure your personal safety.

Safety – Setting up and commissioning – Operation – Spare parts lists
Basic safety instructions
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
WARNING! The use of tools other and accessories than those tools recommended in
this manual, or the performing work with this power tool beyond the intended use, can
lead to accidents.

Handle the cable carefully. Do not use the cable to pull the plug out of the socket.
Protect the cable against heat, oil and sharp edges.

Maintain your tools with care. Keep your tools sharp and clean to be able to work well
and safely. 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. Always keep all switches dry, clean and free from oil and grease.

Check your mobile sheet cuttin
g table incl. accessories for damage. Before use
check the power tools for correct and intended function. Check the moving parts for
damage. All parts must be correctly installed to ensure correct operation of the
machine. Damaged parts and safety devices must be correctly repaired or replaced.
Do not use the machine if the switches are defective. Damaged switches must be
replaced by PFT customer service.

Have the repairs carried out by PFT customer service only. This mobile sheet cutting
table complies with the relevant safety regulations. Repairs may be carried out by
PFT staff only to avoid a risk of accidents for the operator.

This machine is not designed for use in EX areas (areas with risk of explosive
atmosphere).

The operator of the machine
is obliged to comply with the national rules and
regulations.
4.3 Observing the operating instructions

Keep these operating instructions near the machine. It must be ensured that all
persons who are to perform work on the machine are able to view the operating
instructions at any time. In addition to the operating instructions, operating
instructions for the purposes of the Occupational Safety Act and the Working Material
Use Regulations must be provided.

In addition, the operating instructions of the work equipment (milling cutter unit and
saw unit) must be observed. All deviating instructions for use (e.g., for tool changes)
are described in these operating instructions.

All safety information signs and operating instruction signs on the machine must
always be kept in a legible condition. Damaged or illegible signs must be replaced
immediately.

Safety – Setting up and commissioning – Operation – Spare parts lists
Basic safety instructions
2021-03-22 11
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
people within the working area by the machine.
Danger!

After switching off the machine, wait for all moving parts to stop before reaching into
the danger zone.

At least once a day and before each use, perform the following checks:

Check the machine for external damage.

Check the function of all safety devices.
4.5 Basic safety measures during maintenance

The maintenance work stipulated in the operating manual –
adjustment, cleaning,
lubrication, maintenance, inspection, etc. must be carried out on time.

Observe the special information for the individual components in these operating
instructions and in the supplied component manufacturers’ guides.

Before carrying out maintenance work, the following points must be observed:

Use the main switch to switch off the central power supply; lock the main switch and
unplug the mains plug.

Immediately replace any machine parts that are not in good working order.

Use only original spare parts or spare parts of the same type.

After completing the maintenance work
and before starting up the machine,
observe the following points:

Check all previously disconnected connections.

Make sure that all previously removed protective devices and covers, etc. are
installed again correctly.

Make sure that all the tools, materials and other equipment used in the work area
have been removed.

Clean the work area.

Make sure that all safety devices of the machine are again working correctly

Safety – Setting up and commissioning – Operation – Spare parts lists
Special safety instructions for operation
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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
Important!
When working on the electrical equipment:

All work on the electrical equipment of the machine must always
be carried out by qualified electricians only.

Check electrical equipment regularly:

reattach loose connections.

Immediately replace damaged cables or defective equipment.

Use only original spare parts
•
Before all work on the electrical equipment, unplug the mains plug.
Lock the main switch against unintentional switching on.
•
There is a risk of unexpected malfunctions when working on the system as a result of:

a failure or malfunction of the control devices.

external influences acting on the electrical equipment.
•
Never clean electrical equipment with water or similar liquids.
•
No unauthorised modifications may be made to the machine for safety reasons.

Safety – Setting up and commissioning – Operation – Spare parts lists
Technical data BOARDMASTER
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6 Technical data BOARDMASTER
6.1 BOARDMASTER 2500 basic machine Article number 00631891
Dimensions of the working
machine:
Specification Value Unit
Length 3010 mm
Width 1620 mm
Height 1380 mm
Weight:
Specification Value Unit
Net weight BOARDMASTER 139 kg
Weight cutting table 103 kg
Weight machine head 36 kg
6.2 BOARDMASTER 2500 mobile basic machine Article number 00631894
Dimensions of the working
machine:
Specification Value Unit
Length 3010 mm
Width 1620 mm
Height 1380 mm
Weight:
Specification Value Unit
Net weight BOARDMASTER 114 kg
Weight cutting table 78 kg
Weight machine head 36 kg
6.3 BOARDMASTER 3150 basic machine Article number 00631892
Dimensions of the working
machine:
Specification Value Unit
Length 3680 mm
Width 1620 mm
Height 1380 mm
Weight:
Specification Value Unit
Net weight BOARDMASTER 154 kg
Weight cutting table 118 kg
Weight machine head 36 kg

Safety – Setting up and commissioning – Operation – Spare parts lists
Technical data BOARDMASTER
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6.4 BOARDMASTER 4000 basic machine Article number 00631893
Dimensions of the working
machine:
Specification Value Unit
Length 4520 mm
Width 1620 mm
Height 1380 mm
Weight:
Specification Value Unit
Net weight BOARDMASTER 170 kg
Weight cutting table 134 kg
Weight machine head 36 kg
6.5 Electrical connection values
Electrical
Specification Value Unit
Voltage 230V, N, PE, 50 Hz 230 V
Output without external components 1800 W
Max total device rating 3000 W
Fuse 16 A
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. 2000 W

Safety – Setting up and commissioning – Operation – Spare parts lists
Positioning laser (optional)
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7 Positioning laser (optional)
Laser Class 1 as per DIN EN 60825-1:2008-05, = 650 nm, 5 mW
8 Operating conditions
The electrical equipment is only suitable for operation in dry conditions and at ambient temperatures
of -10 °C to 50 °C. Operating under any other conditions is not permissible!
9 Sound power level LWA
Saw unit (manufacturer’s specification) 97.9 dB(A)
Milling cutter unit (manufacturer’s specification) 99.0 dB(A)
Groove sawing unit (manufacturer’s specification) 92.8 dB(A)
10 Pneumatic power unit lifting system
This machine is supplied with a pneumatic power unit lifting system. A pressure regulator installed in the
machine to regulate the air pressure to 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
Material
Gypsum boards, gypsum fibre, cement fibre and hard plasterboard, fibreboard,
chipboard, soft fibreboards, aluminium composite materials and plastic boards.
11.1 BOARDMASTER 2500
Maximum operational load 150 kg
Maximum board size 2500 mm x 1260 mm
Maximum plate thickness 2500 mm x 1260 mm 48 mm

Safety – Setting up and commissioning – Operation – Spare parts lists
Workpiece
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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
Maximum operational load 150 kg
Maximum board size 3150 mm x 1260 mm
Maximum plate thickness 3150 mm x 1260 mm 48 mm
11.4 BOARDMASTER 4000
Maximum operational load 150 kg
Maximum board size 4000 mm x 1260 mm
Maximum plate thickness 4000 mm x 1260 mm 48 mm

Safety – Setting up and commissioning – Operation – Spare parts lists
Proper use of the machine
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12 Proper use of the machine
Danger!
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!
Use only dry plates.
The processed materials must not contain metal parts (such as screws, nails, etc.).
Material may only be fed in with the machine switched off and after the machine
head has been pushed back.
13 Set-up location
The mobile sheet cutting table must be installed in a flat and dry location.
Make sure that sufficient space is available for the mobile sheet cutting table to allow
access from all sides.
The work area lighting must be set up as per national safety regulations.
Power supply cables and hoses must be routed so that they do not cause a stumbling
hazard at the workspace.
Also consider the machine travel range and ensure sufficient cable and hose lengths.

Safety – Setting up and commissioning – Operation – Spare parts lists
Extraction unit
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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.
Ensure sufficient performance in your choice of an extraction unit. The air speed should
be 28 m/s, and the conveying capacity 72 m³/h.
Power is supplied to the extraction unit via the 230 V mains (not via the Boardmaster).
When operating the system make sure the device switch on the extraction unit is set to
“RA" automatic mode. There is no need to press the on/off switch separately, as the
extraction device is controlled by the cutting table. (The Boardmaster is powered via the
extraction system).
Always use an extraction unit for a safe and dust-free work!
NOTE!
After switching off the machine power unit, the extraction unit switches off after a delay
of a few seconds. This is normal operation and serves to clean the entire extraction duct.
NOTE!
Use of an extraction unit that is not recommended by us can lead to injuries and
damage to the system. I
n this case we are not liable for personal or material
damage.

Safety – Setting up and commissioning – Operation – Spare parts lists
Machine structure
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15 Machine structure
The machine consists of 4 assemblies:
15.1 Direction of movement
The direction of movement is divided into longitudinal (X) and transverse (Y)
WARNING! Never use the Y control handle for movements in the Xdirection.
Assembly 1:
Machine table
Assembly 4:
Saw unit
Assembly 2:
Machine head
Assembly 3:
Milling cutting unit
Control handle for
transverse direction (Y)
Control handle for the
longitudinal direction (X) t
Y
Y
X
X

Safety – Setting up and commissioning – Operation – Spare parts lists
Machine structure
20 2021-03-22
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
Fig. 11.01 milling cutter unit right
Fig. 11.02 milling cutter unit left
15.2.2 Sawing with the saw, longitudinally
Fig. 11.03 sawing unit longitudinal – right
Fig. 11.04 sawing unit longitudinal – left
15.2.3 Cross cutting with the saw
Fig. 11.06 sawing unit cross cutting – left
Direction of movement
in operations
Direction of movement
in operations
Direction of movement
in operations