Behringer HBP530A-CNC User manual

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 1
Table of Contents
1 Safety 6
1.1 Machine Hazards 6
1.2 Explanation of Symbols 6
1.3 Qualified Personnel 6
1.4 Proper Operation 7
1.5 The Workplace 7
1.6 Location of the Operating Instructions 8
1.7 Emergency Stop 8
1.8 Common safety regulations 8
1.9 Noise 9
2 Installation 10
2.1 Transport 10
2.2 Foundation 10
2.3 Electrical connections 10
3 Instruction for use 11
3.1 Rust protection paint 11
3.2 Coolant 11
3.3 Saw band choice 11
4 Operation 12
4.1 Description control panel 12
4.2 Switch on and off 12
4.3 Saw frame 13
4.4 Clamping device 13
4.4.1 Material collet 13
4.4.2 Supply gripper 13
4.4.3 Clamping pressure 13
4.4.4 Bunch clamping device (Optional equipment) 13
4.4.5 Vertical vice (Optional equipment) 13
4.4.6 Gantry vise (Optional equipment) 13
4.5 Saw drive 14
4.6 Cutting velocity 14
4.7 Feed and Cutting pressure adjustment 14
4.8 Coolant 14
4.8.1 Swell cooling 14
4.8.2 Spray cooling unit (optional equipment) 15
4.8.3 Temperature range 15
4.9 Sawband change 15
4.10 Supply Carriage 16
4.11 Length location stop nut (LAM) 16
4.12 Chip conveyor (Optional equipment) 16
4.13 Roller train 17
4.14 Point light 17

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 2
4.15
Laser (optional equipment) 17
4.16 Material shaking conveyor (specific equipment) 17
4.17 Cutting control unit (optional equipment) 17
4.18 Auto - Feed - Control (AFC) (optional equipment) 18
4.18.1 Cutting parameter 18
4.18.2 Materials 18
4.18.3 Material width 18
4.19 Cope devise (optional equipment) 19
5 B EHRINGER Terminal BT - 41 20
5.1 Terminal description 20
5.1.1 Menu structure 21
5.1.2 Navigation 22
5.1.3 Function 22
5.1.4 Display - Symbolic 23
5.1.5 Function key: 24
5.2 Main menu (page 1) 25
5.3 Automatic Menu (page 2) 26
5.3.1 Latest state of data (page 66) 27
5.3.1.1.1 Displaying and entering the limit values. ............................................29
5.3.2 Record Data (page 4) 30
5.3.3 Record data 32
5.3.4 Job list (page 49) 34
5.3.5 Job list 35
5.3.6 End piece stop (page 51) 36
5.4 Cutting menu (page 5) 37
5.4.1 Cutting data (page 6) 38
5.4.2 Cutting data 39
5.4.3 Time record (page 7) 40
5.5 Diagnostic menu (page 8) 41
5.5.1 Actual values (page 34) 41
5.5.1.1 Sensors (page 9) 42
5.5.1.2 Digital I/O (page 10) 43
5.5.1.3 Axis Diagnosis (page 45) 44
5.5.1.3.1 Infeet axis (page 43) .........................................................................45
5.5.1.3.2 Counter saw frame (page 53) ..........................................................46
5.5.1.4 Automatic diagnostic (page 50) 47
5.5.1.5 Motor controller diagnosis (pagee 58) 48
5.5.2 Task – Runtimes (page 11) 49
5.5.3 System Inf. (page 15) 50
5.5.4 Alarm System (page 36) 51
5.5.4.1 Actual Alarm (page 37) 52
5.5.4.2 Alarm History (page 38) 53
5.5.5 Service Menu (page 42) 54
5.6 Special functions (page 12) 55
5.6.1 Switching functions (page 13) 56
5.6.2 Control devise (page 14) 59
5.7 Setup (page 16) 61
5.7.1 System (page 17) 61
5.7.1.1 System data (page 19) 62
5.7.1.2 Material list (page 24) 64

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 3
5.7.1.3
Material input (page 57) 65
5.7.1.4 Modem Settings (page 56). 66
5.7.1.4.1 Initialisation......................................................................................66
5.7.1.4.2 Recall number ..................................................................................67
5.7.1.4.3 Start modem operation at BT 41.....................................................67
5.7.2 Password (page 25) 68
Overview BT41 Screen display Password level 69
5.7.3 Machine Constant (page 20) 70
5.7.3.1 Hydraulic system (page 26) 70
5.7.3.1.1 Hydraulic values (page 18)..............................................................71
5.7.3.2 Setting of H&L current regulator (optional) (page 23) 72
5.7.3.2.1 Setting instruction ...........................................................................72
5.7.3.3 Saw Menu (page 39) 73
5.7.3.3.1 Saw General (page 27).....................................................................74
5.7.3.3.2 Saw Thresholds (page 40)...............................................................76
5.7.3.3.3 Cutting conduct (page 41)...............................................................77
5.7.3.3.4 Saw blades (page 48)......................................................................79
5.7.3.3.5 Cutting force regulation (Page 60).....................................................80
5.7.3.4 Clamping devices (page 28) 81
5.7.3.4.1 Material clamp (page 30). ................................................................82
5.7.3.4.2 Feed gripper (page 31).....................................................................83
5.7.3.4.3 Vertical clamp (page 32)..................................................................84
5.7.3.4.4 Portal clamp (page 33).....................................................................85
5.7.3.5 Paraphernalia (page 29). 86
5.7.3.6 Material Transport (page 55). 87
5.7.3.6.1 Infeed Parameter (page 54). ...........................................................88
5.7.4 Axis Menu (page 44) 89
5.7.4.1 Infeed axis (page 46) 89
5.7.4.1.1 Infeed parameters (page 35). ..........................................................90
5.7.4.1.2 Automatic Data (page 47)................................................................92
5.7.5 Motor Controller (page 52). 94
5.7.5.1 Motor controller parameterise 94
5.7.5.2 Motor controller read-out 95
6 Automatic operation 96
6.1 Reference movement 96
6.1.1 Common conditions! 96
6.2 Automatic start 96
6.2.1 Basic condition 96
6.2.2 Start without Material 97
6.2.2.1 Manual material infeed 97
6.2.2.2 Automatic material infeed (optional equipment) 97
6.2.3 Start with Material 97
6.2.4 Inquiry cutting data (optional equipment) 98
6.3 Automatic stop 98
6.3.1 Quantity reached 98
6.3.2 Material end 98
6.3.2.1 Machine without depot 98
6.3.2.2 Machine with depot (optional equipment) 99
7 Sawing cycle (optional equipment) 100

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 4
8
Fault messages 101
9 Safety device/guards 117
9.1 Wheel cover 117
9.2 Motor overloads 117
9.3 Band slip monitor 117
9.4 Breakage band control 117
9.5 Band deflection monitor (Specific equipment) 117
9.6 Coolant flow monitor (Specific equipment) 117
9.7 Coolant level monitor (Specific equipment) 117
9.8 Band location monitor (Specific equipment) 118
9.9 Protective fence (Specific equipment) 118
9.10 Light barrier (Specific equipment) 118
10 Maintenance 119
10.1 Coolant 119
10.2 Grease lubrication 119
10.3 Gear box 119
10.4 Hydraulic 119
10.5 Chip brush 120
10.6 Carbide blade guides 120
10.7 Wheel cases 120
10.8 Chip conveyor (Specific equipment) 120
10.9 Measuring unit (Specific equipment) 120
10.10 Change of battery 120
10.10.1 Operation steps 121
10.11 Preplacement and Cleaning of Filter Mat 121
10.12 Lubricants 122
11 Troubleshooting 123
12 Ex-operation 124
13 Appendix 124
13.1 Feed in relation to the current regulator position 125
14 B EHRINGER -Cool Jet Lubricate Device (Special Equipment) 126
14.1 Safety 126
14.2 Operation 126
14.2.1 Fundamental function description 126
14.2.2 Switch on and - off of the spray cooling 126
14.2.3 Calibration of the spray jet 126
14.2.4 Calibrate working air pressure 127
14.2.5 Calibrate delivering volume 127
14.2.6 Calibrate spray air volume 127
14.2.7 Proof calibration 127
14.3 Refilling lubricant 127
14.4 Determine the spray stuff consumption 129
14.5 Choice of a spray stuff 130

Operating Instructions
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BA85308
Status 46/04
Rev 07.02.11
Page 5
14.6
Commissioning 130
14.6.1 Net air connection 130
14.7 Maintenance / maintains 130
14.7.1 Automatic condensate emptying 130
14.7.2 Manual condensate emptying 130
14.7.3 Sintered stainless steel filter cleaning 131
14.7.4 Oil container strainer cleaning 131
14.7.5 Sprayoil-lead/micropump bleeding 131
14.8 Disturbance 131
15 Central Lubrication System (Special Equipment) 132
15.1 Structure and Function 132
15.2 Lubricant scope 132
15.3 Commissioning 133
15.4 Operation 133
15.4.1 General 133
15.4.2 Refill Lubricant 133
15.5 Lubricant selection 133
15.6 Maintenance 133
15.7 Lubricant points and pipe ways 134
15.8 Troubleshooting 134
EC-Conformity Declaration

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 6
DISCLAIMER:
Please note that the following is a translation from the German original.
While every endeavour has been made to provide a complete and faithful
translation, in the case of litigation the original text shall prevail.
1 Safety
1.1 Machine Hazards
Awareness of and strict adherence to the safety instructions and warnings incorporated in
the Operating Instructions are a fundamental prerequisite for the safe installation,
commissioning, maintenance and operation of this machinery. Only qualified personnel
have the requisite specialist knowledge to correctly interpret and implement the general
instructions and warnings pertaining to hazards contained herein. This machinery was
designed and built to conform fully with all current health and safety legislation, in
particular the German 'Prevention of Accidents Regulations'
(Unfallverhütungsvorschriften). Notwithstanding this conformity, improper operation of this
equipment can render it a danger to life and limb for the operator and other persons.
1.2 Explanation of Symbols
The following symbols are used in the Operating Instructions:
Danger!
denotes an immediate danger. Ignoring this warning can result in serious
personal injury.
Danger!
denotes an immediate electrical danger. Ignoring this warning can result in
serious personal injury.
Important!
denotes user hints and tips and other useful information.
1.3 Qualified Personnel
Non-qualified personnel must not operate this machinery. Disregarding the warnings
contained in the Operating Instructions and the safety stickers on the machinery can lead
to material damage and serious personal injury. The minimum age for operating machinery
as prescribed under local law must also be observed. Only qualified personnel may
operate this machinery.
Qualified personnel are:
•Operators who have been instructed in the proper operation of this machinery and who
have read and understood the relevant sections of the Operating Instructions.
•Commissioning and service engineers who have been trained on this equipment and
are authorised to carry out repairing on this machinery.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 7
1.4 Proper Operation
The sawing machine described herein is intended solely for the sawing of metal and metal-
related materials within the capacity dimensions outlined in the data sheet. Consultation
should be taken with the manufacturer before sawing any other material. This machinery
must only be used in an explosion-safe environment. The ambient temperature must stay
between +5°C and+40°C. The installation of a coolin g or heating system (specific
equipment) is necessary by higher or lower temperatures. The machine should never stay
outdoor and must be protected from rain and snow.
This machinery was designed, built and tested in conformance with current health and
safety standards. These standards were also considered in the compilation of
documentation. Under normal operation condition this machinery can be deemed to be
safe assuming the safety instructions are considered and the given warnings are heeded.
For proper operation please observe the following points:
•Operators must be aware of the potential risks and hazards as well as the safety
equipment incorporated in this machinery.
•Safety equipment, such as emergency stops and covers, must not be removed or
rendered inoperative.
•In front and behind of the sawing machine are to place if necessary tables, roller tables
and containers that no pieces are able to fall down. Proud materials are if necessary to
support.
•The requirements contained in the Operating Instructions pertaining to operation,
maintenance and servicing of this machinery must be strictly adhered to.
•Unauthorised alterations or modifications to this machinery are prohibited.
Danger!
Do not reach into the work zone of the machine during operation.
Deviations from normal operation (e.g. increases in power consumption, temperature or
vibration, or unusual noises) indicate that the function of the machinery is impaired. In
order to avoid faults, which could result in immediate personal injury or material damage,
the relevant maintenance personnel should be alerted without delay.
If in doubt, switch the machine off!
Important!
Damage caused as a result of non-adherence to the Operating Instructions
is not covered under warranty.
1.5 The Workplace
The workplace is the area in front of the operator console. The operator should remain at
the workplace when the machine is working.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 8
1.6 Location of the Operating Instructions
The Operating Instructions should be kept on hand in the vicinity of the machine at all
times.
Important!
Damage caused as a result of non-adherence to the Operating Instructions
is not covered under warranty.
1.7 Emergency Stop
The machine can be shut down as follows:
•corresponding operation of the control unit
•by activating the emergency stop,
•opening the protection hoods
•opening the safety guards (if existing).
Danger!
Protective plates and covers prevent access to the machine. They are
designed to protect operators and other persons and must not be removed
or modified.
1.8 Common safety regulations
•During cleaning-, maintenance work and repairing switch off the main switch and
support the saw frame!
•Never grip during the sawing process in the sawing- or clamping zone! Attention the
machine lags!
•The operator is responsible that during the working process no person is in the danger
zone (supply- or dispatch-table roller, measure car, angle adjustment etc.)!
•During the dead man working process the necessary regulations are to observe!
•If there are disturbance or to do manual doings, during the automatic process always
switch over into the manual process!
•Repairing at the electric device only from the electric expert.
•The machine is always to switch off before repairing are done at the electric device! The
machine is to protect against re-switch on!
•If the main switch is switched off however some parts of the machine are alive, for
example:
- Hydraulic oil- or coolant-heatings
- Switchgear cabinet plug socket
- Switchgear cabinet lighting set

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 9
1.9 Noise
Bandsaws generate a noise level of approx. 75 dB(A), measured at the workplace with the
machine in idle running.
When the saw band enters the cut, noise levels can increase depending on the grade and
shape of the material being sawn.
On solid material 80-85 dB(A) is rarely exceeded. Particularly when cutting thin-walled
sections, however, noise emission can increase to a maximum of 90 dB(A), measured at 1
metre from the point of cut.
Important!
Wearing of ear plugs!

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 10
2 Installation
2.1 Transport
The machine can be suspended for transporting by boreholes at the machine column. By
the transport with the fork truck it is to look for a continues weight distribution on both
forks. The centre of gravity of the machine is in the region of the saw bow.
2.2 Foundation
For a professional assembly the foundation is to be build after the supplemented drawing.
The plainness of the floor should have +0 / -10 mm. An adequate concrete quality is B25.
If necessary the customer has to arrange a static calculation.
The machine must be fixed at the floor with foundation bolts this particularly if is in relation
with roller conveyors and measuring device.
That the coolant does not flows to far backward on the long work piece surfaces, an
assembly with a slight incline to the cutting side is recommended.
2.3 Electrical connections
Attention!
Never do any work at the electrical parts before the electricity is
disconnected.
Make sure that not unauthorised electricity will be switched on.
Before connecting it is to proof, if the operating voltage of the net is identical with the
voltage of the driving motor.
The sawing machine is installed. It is only to feed the power supply cable into the switch
gear cabinet and the cable is to connect at the binding screws L1, L2, L3 and PEN. At
these binding screws it has to be a right hand rotary field. The right turning direction can
be seen by switch on of the hydraulic. If the manometer shows pressure for the plant after
switch on, the rotary direction is correct.
The change of the turning direction is only to attain by changing the two outward ladder of
the connection cable.
After connecting the machine the control voltage is to proof. If the control voltage is higher
than 26 V or less than 22 V the control transformer from the lead side, is to regulate for the
higher or lesser voltage.
Attention!
After an operation time from 1 week, the binding screws of the switchgear
and the binding screws in the switchgear cabinets have to be strongly
tightened.
When a customer uses a Residual Current Circuit-Breaker, he must use a so-called "All
Current Sensitive Residual Current Circuit-Breaker 300mA". A 300mA Residual Current
Circuit Breaker offers protection with indirect contact and also fire protection which is
customary and satisfactory with industrial facilities.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 11
3 Instruction for use
3.1 Rust protection paint
The taper gibs of the clamping fixtures and all other guides have to be cleaned from the
rust protection paint by kerosene and lubricated before the first operation starts.
3.2 Coolant
It is to fill coolant in the coolant container. The volume that is to fill in can be read in the
technical data. We recommend B EHRINGER -High Speed-Coolant-Concentrate with an
mixture relationship of 1:5 to 1:10 with water. It is to make sure that the concentrate is
filled in the water and not vice versa. The mixing should be done by strong stirring.
If there is a danger of freezing it is additional to fill in anti-freezer (mixture relationship see
producer instructions).
3.3 Saw band choice
The dimensions of the saw band is to find out in the cover. For economical sawing we
recommend Behringer-HSS-Bimetal Saw bands with variable tooth pitch.
A relation of working length to tooth pitch is shown in the below chart :
working length
tooth pitch
up to 100 mm 4-6 TPI
80-150 mm 3-4 TPI
120-220 mm 2-3 TPI
from 250 mm 1,4-2 TPI
We will gladly advice you for using specific sawblade qualities for different materials e.g.
hard alloy. Please consult our sales service or our agency.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 12
4 Operation
A T T E N T I O N R I S K O F A C C I D E N T!
Never grip during a switched on machine in the clamping zone and in the
zone of the saw bow!
Always take care, that no one is in the working area of the tools (saw
band).
A T T E N T I O N
In manual mode it is important to pay attention, that no collision during
the different movements happen. The operation of the movements in
manual mode is the responsibility of the machine operator!!!!
4.1 Description control panel
Net control:
Shines white as soon as the main
switch is switched on and a
control voltage of 24 V is active.
Two hand operation
This key is used for several
operation tasks.
Interruption
This illumining indicator shows a
interruption of the machine by a
red flashing.
Point light *
With this switch is the point light
switched on respectively – off.
Mode pre-selection
With this switch is pre-selected
between automatic- and manual
operation.
Roller train *
With this switch the actuated roller
trains are moved.
* = Optional equipment
4.2 Switch on and off
The automatic sawing machine is switched on at the main switch. In the zero position the
switch can locked up with three padlocks. By pressing the emergency cutout the control
voltage is switched off and hence the machine is repealed. The unlocking of the
emergency cutout is to do by turning the red button. After the main switch is switched on
and the emergency cutoff is unlocked then the machine is to start in manual operation with
the function key “Hydraulic on”. This is indicated by the LED. If the sawing machine did not
operate longer then approx. 15 minutes the control unit will switch off the hydraulic pump.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 13
4.3 Saw frame
For lifting and lowering the sawframe it is necessary to actuate the function key “SR lift /
lower” (for “lifting” 2-hand operation). The sawframe is to lower so deep until the button
behind the sawband touches the sawing material. The lifting of the sawframe is also
possible by a switched on sawbanddrive. After the cut is finished the sawframe lifts up in
the automatic procedure over the material top edge. The distance between sawband and
material top edge is determined in the control procedure. During manual operation the
sawframe stays in his lowest position.
4.4 Clamping device
4.4.1 Material collet
The stationary attached vise is called material collet. To open or close the material collet
(for “clamp” 2-hand operation) is to do by the functiion key “MZ open / MZ clamp”. During
the switch on of the sawbanddrive the material collet closed and clamps the material for
the whole sawing process.
4.4.2 Supply gripper
The vice which is attached at the supply carriage at the machine is called supply gripper.
The opening and closing (additional for clamping two hand operation) is to do by pressing
the corresponding function key “NG open” / “NG clamping”.
4.4.3 Clamping pressure
For thin walled profiles it is possible to reduce the clamping pressure, that the fixed
material is not deformed. This adjustment is to do at the knurled screws at the pressure-
relief valve. The setted pressure is to read at the manometer.
4.4.4 Bunch clamping device (Optional equipment)
The bunch clamping serves for clamping several rods in different layers. It is mounted at
the gripping jaw or at the horizontal gripping jaw and connected with the hydraulic rapid
clutch. The clamping zone is to take out of the order confirmation.
4.4.5 Vertical vice (Optional equipment)
If the machine is equipped with a vertical vice, then the clamping devise is actuated with
the functions key “VS open and VS clamp” (for “clamp” 2-hand operation). The vertical vice
is only to clamp if it is active. The actuation does happened by the operation panel (see
menue page 13 special functions).. Just as the vertical vice is clamped by a switched on
drive motor.
4.4.6 Gantry vise (Optional equipment)
If the machine is equipped with a gantry vise, then the same is valid as for the vertical vise.
The gantry vise is also to activate before. The actuation does happened by the operation
panel. (see menue page 13 special functions).

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 14
4.5 Saw drive
Before starting the sawing operation, the material must be clamped through
the material gripper (point 5.4.1).
By pressing the function key “SA on/off” the sawdrive is switched on (for “saw on” 2-hand
operation). Simultaneously the coolant pump and the chip conveyer are switched on,
additional the band guides are clamped hydraulically. By pressing the function key “SA
on/off” the sawdrive and the secondary aggregates are switched off.
4.6 Cutting velocity
The automatic sawband is equipped standard with a infinitely adjustable cutting velocity. It
is adjusted in the menu “cutting data” (page 6). Reference values for the velocity
adjustment are to read from the chart in the appendix. The band velocity may not to fast if
the coolant pump is switched off, because a overheating of the band guide is to avoid.
4.7 Feed and Cutting pressure adjustment
The feed velocity is to adjust infinitely at the stream-regulating valve;
With the cutting pressure regulator; the hydraulic overload valve is pre-stressed
corresponding to the sawing material.
- For profile material: Adjustment 1 - 3
- For standard steel, as e.g. C 15 - C 45: Adjustment 4 - 6
- For high strength steel: Adjustment 7 - 9
For running in of new sawbands the feed is to reduce for the first cuts approximately 50%
of the standard feed .
During the sawing process for standard solid material the manometer for the cutting
pressure has to show "0" (no pressure);. A pressure rise at this manometer shows that the
overload valve reduces the sawfeed. For profiles the reducing is intent for example if the
sawband saws the flange of a beam.
4.8 Coolant
4.8.1 Swell cooling
After switch on of the saw drive the coolant supply is to adjust to the cutting interstice.
Therefore the closed valves are to open corresponding at the coolant distributor.
At the stationary band guide the coolant is only needed for cooling the carbide jaws and to
rinse chips off.
At the movable band guide the coolant supply should adjust stronger because more
emulsion can flow from here to the cutting interstice.
The intermediate coolant supply at the lifting feeler is only needed for larger material
diameters.
For the sawing process without coolant is it possible to switch off the coolant pump at the
DC-terminal in the menu " specific function" (page 13).
The band velocity may not to fast if the coolant pump is switched off, because a
overheating of the band guide is to avoid.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 15
4.8.2 Spray cooling unit (optional equipment)
If the machine is equipped with a spray cooling unit, it is possible to switch over at the
control panel (menu “specific function” - page 13). This is recommend for thin walled
profiles that have nearly no chip amount. Technical hint take a look at appendix.
4.8.3 Temperature range
The coolant used by company Behringer is determined for a regular temperature range.
Under specific conditions (temperature below 0°C) we recommend to use a suitable
coolant.
If necessary we preparing corresponding your conditions a specific offer.
Annotation: A use of the coolant with an additive of antifreezer is to avoid in case of health
problems. The combination of both are reacting ultimate toxic and are to use only in closed
systems.
4.9 Sawband change
Attention !
The sawing machine lags !
After switch off waiting until the machine stands still !
Never grip in the running tool !
The machine operates in a pull process, that means the tooth peak are showing in the
direction of the chip broach brush number 10; page 1a.
For changing the saw blade it is to do the following steps:
1. The machine is to switch in at the main switch. For an unlocked emergency cut-out it is
to switch in the hydraulic pump by pressing the function key “hydraulic on”.
2. Saw frame lifting up by actuating the key „SR lift“.
3. Opening the protection hood and hinge downward the chip broach brush
4. Switching off the hydraulic pump by the cut-out key.
Attention!
By the handling with the saw band it is to wear gloves!
5. The saw blade is completely to release with the manual wheel number 17, page 1a and
afterwards taking out the saw blade.
Important!
For every saw band change the both band guides have to cleaned
carefully.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 16
6. Lay on a new saw blade. Here it is for a simple assembly the saw blade to hold tied at
the driving side with the saw blade tension spring number 18; page 1a. To introduce
the saw blade into the carbide guides and the roller guides number 11 and 15; page 1a
it is not to use a tool.
7. Now with the auxiliary of the manual wheel the saw blade is stretched until the saw
blade has aligned a little bit.
8. The saw blade is to press again against the shoulder of the wheels and powerful to
stretch. The hydraulic cylinder number 10 does the last blade tension; page 1b while
switching on the hydraulic pump.
9. Chip broach brush is to set again and the protection hood is to close.
Attention!
Before going on with the working process convince yourself from the
right assembly of the saw band.
It is to observe for the right cut pressure for the band tensile.
The tension pressure is shown at the manometer. The right theoretical value is to take
from the technical data.
With a new saw band it is to saw with a reduced feed. For this see chapter "Cutting
pressure adjustment and feed adjustment".
4.10 Supply Carriage
By pressing the switch „NG forward / NG backward“ (2-hand operation) the supply carriage
is to move. For this the sawband is to lift up to the material top edge.
4.11 Length location stop nut (LAM)
After switching on the sawing machine, at first the LAM is to reference. The reference
movement is to start by switching on the hydraulic pump and afterwards actuating the
flashing automatic key. If the reference movement is finished then the LED goes out in the
automatic key. The LAM is to move after switching on the hydraulic and finnishing the
reference movement by actuating the function key „Infeed carriage (NS) forward“ and „NS
backward“. If then the key fast will be pressed , then the LAM moves into the rapid
motion. Therefore it is to change over at the display to menu side 43 (infeed axis).
Simultaneously the actual position of the LAM is to read. The counter has to be between
approx. 2,00 mm in the foremost position and approx. 610,00 mm at the rearmost position
of the LAM.
4.12 Chip conveyor (Optional equipment)
The chip conveyor must be put away from the machine by changing the saw band - it must
be thorough delivered from adhering chips. Then remove the chips located in the pushing-
in-shaft of the conveyor or in the machine base.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 17
4.13 Roller train
If the machine is complemented with a infeed and outfeed roller train, the roller trains with
the specific two stage switches can be moved forward and backward slowly or fast.
Therefore the sawband is to lift over the material top edge. The sawed cuttings can also
shipped away if the sawframe is lifted down.
4.14 Point light
The light serves to sign the shape of the sawband as a shadow at the material. With it
exists a reference line to the manual positioning of the material.
4.15 Laser (optional equipment)
The laser is to switch on by the T-handle. Afterwards the material is to align with the
auxiliary of the ray of the laser. Avoid a direct look into the laser light. Never use optical
auxiliaries because it is possible that the ray of light is narrowed and then produce a
hazard for the eyes.
During the adjusting as well as operations in the area of the laser an appropriate personnel
protection equipment (laser protection glasses) are necessary.
The line laser is a device of cathegory 2.
The operator have to meet the regulations of the national accident
prevention regarding laser radiation (in Germany UVV „ laser radiation“
BGV B2/VBG 93).
Die UVV „Laserstrahlung“ BGV B2/VBG 93 ist einzuhalten
Avoid a direct look into the laser light!!!
4.16 Material shaking conveyor (specific equipment)
The material shaking conveyor works parallel with the saw drive if it is activated from the
terminal (specific functions, page 13).
4.17 Cutting control unit (optional equipment)
This is a system to inspect the cutting line in the cut material. The saw blade divergence is
displayed from the zero line. With two limit switches it is possible to adjust a personal as
well as the allowed tolerance field.
Limit value I is to interpret as information and feed reducer and is displayed with a
message.
With limit value II the machine lifts up, switches off and the fault message “cutting control
limit switch II” appears at the display.
If the limit switch I of the cutting control unit during the saw untrue is occurred then the
sawing feed is reduced by 20% to extend the machine operation time in the death men
operation.
After 30 seconds the cutting line is proofed once again. If the message “limit value I” does
not occur anymore then the standard feed is adjust. If the “limit value I” once again occur
then another 20% reduction of the feed will adjust. If necessary after further 30 seconds
another reduction of the feed from 20% will adjust. If after a third time of the feed reduction
no stabilising will occur then the machine is switched off the saw drive. The cutting control
is to deactivate in the menu “Control unit” (page 14).

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 18
4.18 Auto - Feed - Control (AFC) (optional equipment)
Under AFC it is to understand a control unit for automatical adjustment of the feed and the
cutting velocity corresponding of the entered material width and material group.
The sawing materials are to select from the BEHRINGER material chart. After starting the
saw drive the feed and blade velocity are insert corresponding to the chart reference
values from the control unit. .
With the machine constants „Factor material chart“ (page 27) the cutting power for whole
chart are to in- and decrease. Also it is to change the blade velocity and power per unit in
the menu” cutting data” (page 6).
Also integrated is the cutting control system to control the cutting line inside the cutting
material.
4.18.1 Cutting parameter
Manual operation: To do a correct saw cut, the control unit has to get the corresponding
cutting parameter. This is to do in the manual operation in the menu "Cutting data" (page
6).
Automatic operation: If a job in automatic operation is to machine with the data who are
programmed in the set, then at first it is to jump in the menu "job input" (page 4), and to
enter the correct data.
If the automatic is started with “ saw off” then the job data are taken over.
If the automatic is started with “saw on” then a message occur if with “manual” or “job
data” are sawed further on.
Set change by automatic operation:
In the automatic operation are to machine several sets one after each other. Here by it is
assumed, that the cutting length and quantity are changing, but the material will be the
same. From this reason during the automatcal set change the control units did not accept
a change of the material group and the material width.
4.18.2 Materials
With the several materials corresponding cutting power and blade velocity are setted for
the sawed material. The correct material is to found with the help of the material chart from
the appendix. The entering is to do in the menu "Job input" page 4 .
4.18.3 Material width
For profile materials theoretically the sum of the wall thickness as material width can be
used. However then the resultant feed rate would be relative high. Because of this the
value for the width for profile material should not be smaller that the half real width of the
material.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 19
4.19 Cope devise (optional equipment)
This devise serves for coping the material during manual operation.
Manual cope: Adjusting the coping height with a ruler at the saw frame.
Electronical cope: Entering the coping height at the operation panel at page 27 “common
sawing” “coping at: …. mm”. If the value “000” is entered, then it is sawed through totally. If
a value higher “000” is entered then it will sawed until this position and the machine is
switch off.

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Rev 07.02.11
Page 20
5 B EHRINGER Terminal BT - 41
5.1 Terminal description
The BEHRINGER BT-41 terminal controls the entire machine and allows the machine
specific data (machine constants), and the power parameters for the sawing process to be
programmed.
Additionally, faults are displayed on screen with descriptions to inform the operator of the
machine status. Fault messages are shown independent of the present procedure.
The start-up mask appears when the machine is initially switched on. Simultaneously the
control unit performs a self-check. After the self-check of the control unit, a light bulb test is
performed and the main menu appears on the screen. The machine is now ready for
operation.