DR. BENDER PB RX/SX 12 User manual

DR. BENDER GmbH
Innovative Power Tools
Operating Manual
Powerbox PB RX / SX 12
HF III
Issued 05.2017 PB RX / SX 12 Art. no. 102405 Subject to change
Alle Rechte vorbehalten / All rights reserved
DR. BENDER GmbH • D-75382 Althengstett • Tel [phone] • Fax [phone]
We are on the internet at http://www.dr-bender.de • email: [email protected]

2

3
Declaration of conformity
DR.BENDER GmbH
Innovative Power Tools
EC – Declaration of conformity for machines
(EC-RL 2006/42/EC)
Herewith, the manufacturer,
Dr. BENDER GmbH
Industriestrasse 22
75382 Althengstett
declares that the machine
PB RX / SX 12
PB RX / SX 12 PB RX / SX 12
PB RX / SX 12
conforms with the aforementioned Directive and the following Directives
-Electromagnetic compatibility (EMC) (2004/108/EC)
-Low Voltage Directive (2006/95/EC)
The following harmonised standards have been used for assessment of the appliance:
EN 50144-1
EN 50144-2-1
EN 55014-1
EN 61000-3-2
EN 61000-3-3
EN 55014-2
EN 61029-1
Authorised Person for Documentation:
Min Wei
c/o Dr. Bender GmbH
Industriestrasse 22
75382 Althengstett
Deutschland
DR.BENDER GmbH Althengstett, 30.07.2018
Industriestraße 22
D-75382 Althengstett
Tel. [phone], Fax [phone]
Min Wei, Managing Director
This Declaration does not include Assurance of Product Properties.
The Safety Instructions of the enclosed Product Documentation have to be respected.

4
Contents
Page
Declaration of conformity 3
Contents 4
1.0 Symbol and pictogram description 5
1.1 Function description 7
2.0 General instructions 8
2.1 Technical description 8
2.2 Applications 8
2.3 Safety 9
3.0 Transport and storage 9
3.1 Transport 9
3.2 Storage 9
3.3 Service Interface 9
4.0 Main dimensions and technical data 10
4.1 Dimensions 10
4.2 Technical data 10
4.3 Operating temperatures 10
5.0 Commissioning 11
5.1 Setting up 11
5.2 Mains connection 11
5.3 Powerbox water connection 11
5.4 Operating the Powerbox 12
5.5 Reversing the rotation of the motor 13
5.6 Acknowledge a fault 13
5.7 Powerbox operating concept 14
5.8 Powerbox fault processing 15
5.9 Fault codes 16
5.10 Automatic shut-off in the event of overload 16
6.0 Safety instructions 17
7.0 Repair and maintenance 18
7.1 Daily maintenance 18
7.2 Quarterly 18
8.0 Warranty 19
9.0 General Safety Instructions 19
10.0 Spare parts lists 20
10.1 Powerbox PB RX/SX 12 20

5
Attention
The safety instructions included in this operating manual must be followed!
Custom models and design variants may deviate from the basic type in
technical details. In the event of any discrepancies, we recommend that you
contact DR.BENDER GmbH urgently. Always give the machine type and
machine number in any correspondence.
1.0 Symbol and pictogram description
Warning
Indicates instructions which may endanger your health or the functionality of the unit if
they are not followed. The warranty shall become null and void if you cause defects to
the unit by non-compliance with these instructions.
Warning
Warning of dangerous electrical voltage.
Before work is performed in this specially marked section, the installation of the device
must be separated completely from current (voltage) and must be secured against
unintentional power ON.
Disregard can lead to severe or deadly injuries.
Recycling
Please direct waste to recycling.
Disposal
The customary and regional laws shall be observed for disposal.

6
Safety signs on the machine
Wear safety shoes
Wear gloves
Wear a safety helmet
Wear protective goggles
Wear ear protection
Wear a breathing mask
Pull the power plug before work on the device
Read the instructions

7
1.1 Function description
Carry handle
Mains connection
400 V / 802267
Emergency stop button
Speed control
Mains connection
230 V / 802343
Overload indicator
LEDs
Start button
Stop button
Water
cooling
Connection
Motor
Water
cooling
Air
cooling
Operating and fault code
indicator
Service
Interface

8
2.0 General instructions
2.1 Technical description
The BELUGA SXM with the Powerbox PB RX/SX12 represents a whole new generation of drive units
for stone cutting. The exceptionally comprehensive modular system offers the flexibility needed today when
performing cutting work in concrete and stone. To achieve this, newly developed high-frequency motor
parts are used in the motor. The frequency range is controlled by the frequency converter from 0 - 1000 Hz
integrated into the Powerbox. At 1000 Hz, the rotor reaches a speed of 30.000 min
-1
. A major benefit lies in
the exceptional weight / power ratio (motor power output = 8 kW / weight = 6.5 kg -> 1.2). Using
conventional technology e.g. type BBM33extra (motor power output = 2.4 kW / weight = 13.5 kg -> 0.17) It
means that the weight of the machine has been reduced sevenfold using the high frequency technology.
We have succeeded in running the Powerbox as well as the drive units on a 230V single phase network or
on a 400 V three-phase network. This means that only one piece of equipment is needed for use on both
voltage sources. Further benefits lie in the stepless speed control. This enables the best speed to be
assigned to each tool diameter, in order to attain the best possible cutting speed on the tool. During work,
the speed can be steplessly reduced if you come up against steel reinforcements and thus can be
optimised according to the progress of the work. Here, you can run the unit at much higher cutting speeds
(Attention! depends on the tool) and in doing so, the progress of the job can be speeded up by up to 150%.
With conventional machines, the torque drops very sharply at the higher speeds. Therefore, this advantage
does not apply to conventional machines.
2.2 Applications
The drive units and the related Powerboxes can be used according to the data attached to the information
plate. If you are using custom-built machines, the details on the quotation and the order confirmation also
apply.
The drive units and Powerboxes are essentially Class I appliances, this is only guaranteed by the full high-
quality protection of the residual current circuit breaker.
If suitable saw blades and drill bits are used, a wide range of materials can be cut:
- Concrete (even with strong reinforcement)
- Sandstone and limestone
- All building materials for solid walls
- Asphalt road surfacing
The machine must
-when operating at 230 V:
Be used with an upstream, all-current-sensitive residual current circuit breaker or safety
transformer in order to guarantee the safety of the operator.
- when operating at 400 V:
Be connected to a properly earthed CEE plug socket (CEE 5 pin, 3P+PE 32A 6h – 400V). The
neutral wire is not required.
Be used with an upstream, all-current-sensitive residual current circuit breaker or safety
transformer in order to guarantee the safety of the operator.

9
2.3 Safety
Warning
Before commissioning, check that the mains voltage and frequency match the
data given on the information plate. ± 5 % voltage and/or ± 2 % frequency
deviation are permitted. Repairs may only be performed by suitably qualified
staff based on their training and experience.
In performing repairs, pay particular attention to:
-the technical data and information on the permitted use (commissioning, standard operating
conditions), which are included e.g. in the catalogue, the operating manual, the information plate
details, and other product information.
-the relevant accident prevention regulations
-the correct use of tools
-the use of personal protective equipment
-Powerboxes which are not defective and have not been modified must conform to the relevant
standards and adhere to all required limits with respect to EMC (electromagnetic interference and
interference resistance). The allowed electromagnetic fields are still emitted. Electromagnetic fields
may interfere with the operation of critical electronic devices (e.g. pacemakers). Wearers of
pacemakers should therefore consult their doctor.
-if a generator is used, proper earthing must be guaranteed.
-in the event of use in “sensitive areas” such as airports, hospitals, or public service broadcast
facilities, the technical management on site must be informed of the use of a frequency-controlled
unit.
3.0 Transport and storage
3.1 Transport
Warning
The Powerbox must be inspected for transport damage after receipt. Any
damage present must be recorded in writing.
3.2 Storage
The storage location should be dry, clean, and at a constant temperature wherever possible.
3.3 Service Interface
The Powerbox can communicate
with a computer by means of the
service interface. New software
updates can be imported. Operating
parameters can be displayed.
Please read the separate user
manual for details.

10
4.0 Main dimensions and technical data
4.1 Dimensions
4.2 Technical data
Rated voltage 230 V
Current rating 16 A
230 V
1~ Power consumption 3,700 W
Rated voltage 400 V
Current rating 15 A
400 V
3~ Power consumption 12,000 W
Frequency 50 – 60 Hz
Degree of protection IP 67 -
Cooling medium Air / Water -
Weight 16.5 kg
4.3 Operating temperatures
If the system is cooled by water, the Powerbox attains the cooling water temperature. In the air cooled
version, the housing may attain temperatures of up to 45°C. This is normal and is not a cause for concern.
Therefore, always hold the Powerbox by the carry handle provided.

11
5.0 Commissioning
5.1 Setting up
Set up the Powerbox at a distance suitable for your work on a level surface, so that you can work
comfortably without the risk of tripping over the Powerbox.
5.2 Mains connection
Attention
Check whether the mains voltage matches the voltage given on the information
plate.
Remove the protective covers on the plug sockets. These protective
covers are designed to protect the socket against the ingress of
water when the plug is not connected. This significantly increases
the service life of the high-quality cable sockets.
First connect the electrical connection cable to the flange socket
found on the front of the Powerbox. Check that the connection cable
is properly connected. Only this will give you the required IP 67
protection. The connection cable used (400 V 3~ or 230 V 1~)
determines whether the Beluga drive unit operates at 230 V, 1~,
4,000W or at 400 V, 3~, 8,000 W. Connect the Powerbox PB RX /
SX 12 to the mains via an upstream, all-current-sensitive residual
current circuit breaker or safety transformer and coded CEE plug 6
h.
Only use extension cables with earth conductors and of sufficient
diameter. If the diameter is too small, this may lead to excessive
power loss and to overheating of the motor and cable. An extension
cable must be protected by an overload switch. Recommended wire
diameters:
Rated current = 15 / 20 A
Cable length m 7.5 15 25 30 45 60
Wire diameter: mm
2
4 4 4 4 6 6
5.3 Powerbox water connection
The Powerbox can be operated air-cooled as well as water-cooled. The air connection normally suffices for
the 8 kW drive units. The water must first flow through the Powerbox, then through the drive unit and only
then to the saw blade or the drill bit. Therefore, connect the water supply to the water line (with tap)
provided on the Powerbox. The water outlet of the Powerbox is connected to the water inlet of the drive
unit.
Attention: If possible do not exceed maximum water pressure of 3
bar
During operation, always supply sufficient cold cooling water (cooling
water should not exceed 30 °C). The machine must be operated
during full load operation with at least 1/2 litre of water per minute.
Only use clean tap water, no contaminated or waste water, since
otherwise the heat transfer to the cooling surfaces is no longer
guaranteed and the motor may suffer irreparable damage.

12
5.4 Operating the Powerbox
After applying the voltage when the motor is connected, the
Powerbox reads the motor type as well as the input voltage and
configures the drive system accordingly. As soon as this action
is completed, the Powerbox will switch to standby, which is
indicated by a flashing green LED on the control panel of the
Powerbox.
The green start button can now be pressed. The Powerbox
switches to operating mode and indicates this in turn by a
permanently lit green LED.
By preselecting a speed in the middle of the control panel, the maximum speed of the motor can be set to 0
- 100% of the rated speed of the motor. The maximum speed is reached when the hand wheel is turned all
the way to the right. This setting defines the range from zero to
the final speed. This speed range is then available to you on
the start switch on the handle of the unit. The connected motor
can now be operated using its controls.
During operation, the three yellow LEDs indicate the load
condition of the motor. After work and during breaks, the
Powerbox is switched off by pressing the red stop button. This
prevents the motor from accidentally restarting.
Green LED
Green LED flashes = standby
Green LED lit= machine on
Switch the Powerbox to operating mode with the green start button on the Powerbox.
Green LED
Green LED = O. K.
The three yellow LEDs indicate the load condition of the motor. The left-hand LED starts to light up at 60 %
of the rated current of the motor. The two right-hand LEDs light up from 80 % of the rated current. You can
work permanently in the yellow zone, this will not damage the machine.
Red LED
Red LED flashes / is lit = fault (fault code can be read in the inspection glass on the top of the Powerbox).
If the red LED comes on, the machine has exceeded the temperature range. The drive unit then shuts
down. Wait until the drive unit has cooled and restart the drive unit with the green button on the Powerbox
The red LED also comes on if there is a fault existing, the drive unit then shuts down. This mainly happens
due to a sudden, very high overload (motor seized). The drive unit is then switched off for your safety.
When the unit is switched on again with the green button, the red LED goes out and the green LED
indicates standby mode again (reset function).
If the red LED does not go out and the green LED is not lit, there is a fault on the Powerbox or the drive
motor. In this case, contact an authorised service centre.

13
Emergency stop button
If sudden danger occurs, the system can be shut down by pressing the
emergency stop button on the front of the Powerbox. This action can also be
performed by a third person. It is therefore important to always set up the
Powerbox at some distance from the work area.
When you have finished your work, switch off the system with the red stop
button.
5.5 Reversing the rotation of the motor
Using motors for hands-free saw applications (e.g. SXM), the rotation can be reversed for flush cuts.
To do so, proceed as follows:
The Powerbox must be in standby mode (green LED flashes).
Keep the red stop button pressed. At the same time, press the green start button for approx. two seconds
until all LEDs are lit on the Powerbox control panel.
Release the green and the red button again.
The rotation of the motor has been reversed.
Follow the steps above to restore the previous direction of rotation. This setting is retained until the
Powerbox is disconnected from the mains.
5.6 Acknowledge a fault
In the event of a fault, this is indicated by a flashing red LED on the control panel of the Powerbox. The
fault code / codes can then be read through the round inspection glass on the top of the Powerbox.
The fault codes are indicated in sequence, digit by digit.
Example:
F-0-5-F-0-9 means fault 05 and fault 09 have occurred.
After the cause of the fault has been rectified, the fault can be acknowledged by pressing the green start
button. The Powerbox is in standby mode again.

14
5.7 Powerbox operating concept.
Power on
Standby
green 500 ms
Box
on / ready
green LED on
Red button on box
Motor
connected
Green button
on box

15
5.8 Powerbox fault processing
Wait for fault
Shut off drive and
stop control unit
Red LED flashes
Wait for green button on Powerbox
or automatic reset
Clear fault
Jump to
standby

16
5.9 Fault codes
Fault code Fault description Troubleshooting
F00, F01 Power supply fault 1. Bring box for repair
F02 Phase failure 1. Check power supply for:
-
completeness of phases
- load capacity of phases
F03 Open circuit on motor 1. Check the motor connectors for dirt and
damage
2. Bring box for repair
F04 Overvoltage in DC link 1. Check power supply
F05 Motor overcurrent 1. Run the motor with less power
F07 Powerbox overheating 1. Allow the Powerbox to cool, check the function
of the fan, if necessary refit the water cooling
circuit
F51 Motor overheating
1. Run motor with less load or increase cooling
water flow rate.
Attention: Regular overheating in the motor
shortens the service life!
F09 Speed sensor fault 1. Check the motor connectors for dirt and
damage
2. Bring motor and box for repair
F12 Earth leakage 1. Check the motor connectors for dirt and damage
2. Bring motor for repair
F13, F14 Internal hardware fault 1. Disconnect box from mains, bring box for
repair if fault reoccurs
F15 Release fault 1. Check emergency stop
2. Check the motor connectors for dirt and
damage
F20 Undervoltage 1. Check power supply
F21 Overvoltage 1. Check power supply
F52 Axis controller watchdog 1. Disconnect the Powerbox from the mains for
10 seconds
F53 Start protection 1. Release handle switch on motor
F62 Safety coupling engaged 1. Restart motor
F63 Motor communication interrupted 1. Check earth conductor 2. Disconnect the Powerbox from the mains for
10 seconds
5.10 Automatic shut-off in the event of overload
As already described under 5.4, the drive unit shuts off in the event of constant overload. The unit is reset
by pressing the green button again.

17
6.0 Safety instructions
Attention
The units must be attended when in use. Disconnect the mains plug and
check that the switch is disabled,
-if the units remain unattended
-during assembly and disassembly
-in the case of a voltage dip (below 200V or below 340V),
-if the mains voltage fluctuates (phase imbalance) or in case of interruption of a phase (phase
failure),
-For adjusting or fitting an accessory.
Switch the machine off if you stop operation for any reason. This prevents the unit from suddenly starting
when unattended.
Do not use the unit when
-a part of the housing is missing or defective,
-there is damage to switches, lines, or plug connections (daily inspection!)
-When operating the units, cooling water must not penetrate the electrical components in whichever
location the units are used.
-If water is dripping from the unit, stop work and take the unit to an authorised service centre.
-After a break in operation, only switch on again if the saw blade or drill bit can rotate freely.
-Check the work area with a pipe detector in order to avoid cutting into electrical cables, water
pipes, or gas pipes etc.

18
7.0 Repair and maintenance
Warning
Always disconnect from the mains before starting repair or maintenance work.
After any repair, the unit must be checked by a qualified electrician (legal
requirement pursuant to VBG4 since 1.1.1990).
7.1 Daily maintenance
Check that no water is leaking out of the unit. This may impair the electrical safety of the unit. In this case,
please contact an authorised service centre.
Visual inspection for damage to the switches, the lines, or the plug sockets.
Clean the units after completion of the work.
Check that no water gets into the units during cleaning.
Drain the cooling water after using the machine. To do so, hold the Powerbox at a slight angle without the
water lines. The water can then drain out through the connections. Alternatively you can also remove the
water line fittings. The cooling circuit then runs faster and is completely empty. It is particularly important to
completely drain the water during frost formation in the winter months.
7.2 Quarterly
Have the cables, switches, plugs checked by a qualified specialist (provision pursuant to VBG4) and record
this.

19
8.0 Warranty
Pursuant to our Terms & Conditions of Sale, we offer a warranty of 12 months from the date of purchase.
This covers the free repair of material and production defects which are shown to have been caused prior
to sale.
An original sales receipt must always be produced when asserting a warranty claim. It must include the full
address of the dealer, purchase date, and type code of the product. The user manual for the relevant
product as well as the safety instructions must have been followed.
Damage caused by operating errors is not covered by the warranty.
The manufacturer’s products are developed and built for specific applications. If the product is used for
purposes other than the intended purpose based on the user manual, or in the event of misuse, or if
unapproved accessories are used, the warranty shall become null and void.
The products must be regularly maintained and cleaned according to the instructions in the user manual.
The warranty shall become null and void in the event of an intervention by third parties (opening the
machine).
The warranty does not cover maintenance and cleaning work.
You must ensure that only original spare parts and accessories are used. The products must be purchased
from an authorised dealer. If non-original parts are used, this may result in consequential damage and
increased risk of accidents. The manufacturer is not liable for such damage. Disassembled, partially
disassembled units, and units repaired with third party parts are not covered by the warranty.
Certain parts are subject to normal wear and tear depending on use. These parts include e.g. carbon
brushes, ball bearings, switches, mains cables, seals, etc. These consumable parts are not covered by the
warranty. Consumable parts are highlighted in the spare parts lists.
9.0 General Safety Instructions
The general safety instructions can be found in the supplied safety instruction booklet.

20
10.0 Spare parts lists
10.1 Powerbox PB RX/SX 12