Behringer HBP530A-CNC

The BEHRINGER HBP530A-CNC is an automatic sawing machine designed for cutting metal and metal-related materials within specified capacity dimensions. It is controlled by the BEHRINGER BT-41 terminal, which allows for programming machine-specific data (machine constants) and power parameters for the sawing process. The machine displays fault messages with descriptions to inform the operator of its status, independent of the current procedure.

Safety and Operation:

The machine is designed for safe operation, provided that safety instructions and warnings are strictly adhered to. Only qualified personnel should operate the machinery. The workplace is in front of the operator console, and the operator should remain there during operation.

Machine Hazards: Operators must be aware of potential risks and hazards. Safety equipment, such as emergency stops and covers, must not be removed or rendered inoperative. Tables, roller tables, and containers should be placed in front of and behind the machine to prevent pieces from falling. Proud materials should be supported if necessary. Unauthorized alterations or modifications are prohibited.
Emergency Stop: The machine can be shut down by operating the control unit, activating the emergency stop, opening protection hoods, or opening safety guards. Protective plates and covers are designed to prevent access and must not be removed or modified.
Common Safety Regulations: During cleaning, maintenance, and repair, the main switch must be off, and the saw frame supported. Never grip into the sawing or clamping zone during operation. The operator is responsible for ensuring no one is in the danger zone during the working process. Manual operations during automatic processes require switching to manual mode. Electrical repairs must only be performed by an electric expert, with the machine switched off and protected against re-switching. Some parts, like hydraulic oil or coolant heating, switchgear cabinet plug sockets, and lighting sets, may remain live even when the main switch is off.
Noise Emission: Bandsaws generate approximately 75 dB(A) in idle running. Noise levels can increase to 80-85 dB(A) for solid materials and up to 90 dB(A) for thin-walled sections. Wearing earplugs is recommended.

Installation:

Transport: The machine can be suspended for transport using boreholes at the machine column. When using a fork truck, ensure continuous weight distribution on both forks, as the center of gravity is in the saw bow region.
Foundation: A professional assembly requires building a foundation according to the provided drawing, with a floor flatness of +0 / -10 mm and concrete quality B25. A static calculation may be necessary. The machine must be fixed to the floor with foundation bolts, especially when connected to roller conveyors and measuring devices. A slight incline to the cutting side is recommended to prevent coolant from flowing too far backward on long workpieces.
Electrical Connections: Never work on electrical parts without disconnecting the electricity and ensuring it cannot be unauthorizedly switched on. Verify that the operating voltage matches the driving motor's voltage. The power supply cable connects to L1, L2, L3, and PEN binding screws in the switchgear cabinet, ensuring a right-hand rotary field (indicated by manometer pressure after hydraulic switch-on). The turning direction can be changed by swapping two outward ladders of the connection cable. Control voltage should be checked and regulated if outside 22-26V. After one week of operation, binding screws in the switchgear cabinets must be tightened. If a Residual Current Circuit-Breaker is used, it must be an "All Current Sensitive Residual Current Circuit-Breaker 300mA" for indirect contact and fire protection.

Instruction for Use:

Rust Protection Paint: Taper gibs of clamping fixtures and other guides must be cleaned of rust protection paint with kerosene and lubricated before the first operation.
Coolant: The coolant container must be filled with coolant according to technical data. BEHRINGER-High Speed-Coolant-Concentrate with a 1:5 to 1:10 mixture ratio with water is recommended. Concentrate should be added to water, not vice versa, with strong stirring. Anti-freezer can be added if there is a risk of freezing (refer to producer instructions for mixture ratio).
Saw Band Choice: Saw band dimensions are found in the cover. Behringer-HSS-Bimetal Saw bands with variable tooth pitch are recommended for economical sawing.
- Working Length to 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
- Consult sales service or agency for specific sawblade qualities for different materials (e.g., hard alloy).

Operation Features:

Control Panel:
- Net Control: White light indicates the main switch is on and 24V control voltage is active.
- Interruption: Red flashing indicates a machine interruption.
- Mode Pre-selection: Switches between automatic and manual operation.
- Two-hand Operation: Used for various tasks.
- Point Light (Optional): Switches the point light on/off.
- Roller Train (Optional): Moves actuated roller trains.
Switch On/Off: The machine is switched on at the main switch (lockable with three padlocks in zero position). Pressing the emergency cutout switches off control voltage. Unlocking the emergency cutout involves turning the red button. After switching on the main switch and unlocking the emergency cutout, start in manual operation with the "Hydraulic on" function key (indicated by LED). If the machine is inactive for approximately 15 minutes, the control unit switches off the hydraulic pump.
Saw Frame: To lift and lower the saw frame, actuate the "SR lift / lower" function key (2-hand operation). The saw frame lowers until the button behind the saw band touches the material. Lifting is also possible with the saw band drive switched on. After a cut, the saw frame automatically lifts over the material top edge. The distance between saw band and material top edge is determined by the control procedure. In manual operation, the saw frame remains in its lowest position.
Clamping Device:
- Material Collet: The stationary vise. Open/close with "MZ open / MZ clamp" function key (2-hand operation). Clamps material during the entire sawing process when the saw band drive is on.
- Supply Gripper: Attached to the supply carriage. Open/close with "NG open" / "NG clamping" function key (2-hand operation).
- Clamping Pressure: Adjustable via knurled screws at the pressure-relief valve. Manometer displays the set pressure. Reduces clamping pressure for thin-walled profiles to prevent deformation.
- Bunch Clamping Device (Optional): Clamps multiple rods in layers. Mounted at the gripping jaw or horizontal gripping jaw, connected via hydraulic rapid clutch. Clamping zone specified in order confirmation.
- Vertical Vice (Optional): Actuated with "VS open and VS clamp" function key (2-hand operation). Clamps only when active. Actuation via operation panel (see menu page 13, special functions). Clamps when drive motor is switched on.
- Gantry Vise (Optional): Similar to vertical vice. Must be activated via operation panel (see menu page 13, special functions).
Saw Drive: Before sawing, material must be clamped by the material gripper (point 5.4.1). Pressing "SA on/off" (2-hand operation) switches on the saw drive, coolant pump, and chip conveyor, and hydraulically clamps band guides. Pressing "SA on/off" again switches off the saw drive and secondary aggregates.
Cutting Velocity: Infinitely adjustable via the "cutting data" menu (page 6). Reference values are in the appendix. Avoid fast band velocity if the coolant pump is off to prevent band guide overheating.
Feed and Cutting Pressure Adjustment: Feed velocity is infinitely adjustable via the stream-regulating valve. Hydraulic overload valve is pre-stressed according to the material.
- Profile material: Adjustment 1-3
- Standard steel (e.g., C 15 - C 45): Adjustment 4-6
- High strength steel: Adjustment 7-9
- For new saw bands, reduce feed by approximately 50% for initial cuts.
- For standard solid material, the manometer for cutting pressure should show "0" (no pressure). A pressure rise indicates the overload valve is reducing saw feed. For profiles, reduction is intended when the saw band cuts the flange of a beam.
Coolant:
- Swell Cooling: After saw drive switch-on, adjust coolant supply to the cutting interstice by opening valves at the coolant distributor. Coolant is needed at the stationary band guide for cooling carbide jaws and rinsing chips. The movable band guide requires stronger coolant supply. Intermediate coolant supply at the lifting feeler is only for larger material diameters.
- Spray Cooling Unit (Optional): Switchable via control panel (menu "specific function," page 13). Recommended for thin-walled profiles with minimal chip amount. Technical hints in appendix.
- Temperature Range: Behringer coolant is for regular temperatures. For temperatures below 0°C, a suitable coolant is recommended. Avoid using coolant with anti-freezer additives due to toxicity in open systems; use only in closed systems.
Saw Band Change:
- Safety: The machine lags; wait until it stops after switch-off. Never grip the running tool. Wear gloves when handling the saw band.
- Procedure:
  1. Switch on machine at main switch. Unlock emergency cutout. Switch on hydraulic pump by pressing "hydraulic on."
  2. Lift saw frame by actuating "SR lift."
  3. Open protection hood and hinge down the chip broach brush.
  4. Switch off hydraulic pump by the cut-out key.
  5. Release saw blade completely with manual wheel (number 17, page 1a) and remove.
  6. Clean both band guides carefully with every saw band change.
  7. Lay on a new saw blade. Hold it tied at the driving side with saw blade tension spring (number 18, page 1a). Introduce the saw blade into carbide guides and roller guides (numbers 11 and 15, page 1a) without tools.
  8. Stretch the saw blade slightly with the manual wheel.
  9. Press the saw blade against the shoulder of the wheels and stretch powerfully. The hydraulic cylinder (number 10) performs the final blade tension when the hydraulic pump is switched on.
  10. Reset chip broach brush and close protection hood.
- Verification: Ensure correct saw band assembly before continuing. Check tension pressure on the manometer against technical data. For new saw bands, use reduced feed (see "Cutting pressure adjustment and feed adjustment").
Supply Carriage: Moves by pressing "NG forward / NG backward" (2-hand operation). Saw band lifts to material top edge.
Length Location Stop Nut (LAM): After switching on, reference the LAM by switching on the hydraulic pump and actuating the flashing automatic key. The LED goes out when reference movement is finished. Move LAM by actuating "Infeed carriage (NS) forward" and "NS backward." Pressing the key fast moves LAM into rapid motion. Display shows actual position (menu side 43, infeed axis). Counter should be between approximately 2.00 mm (foremost) and 610.00 mm (rearmost).
Chip Conveyor (Optional): Must be moved away from the machine for saw band changes. Thoroughly clean adhering chips from the conveyor's pushing-in-shaft or machine base.
Roller Train: If equipped with infeed and outfeed roller train, they can be moved slowly or fast with specific two-stage switches. Saw band lifts over material top edge. Sawed cuttings can be shipped away when the saw frame is lifted down.
Point Light: Projects a shadow of the saw band shape onto the material, providing a reference line for manual material positioning.
Laser (Optional): Switches on with the T-handle. Align material using the laser ray. Avoid direct eye contact with laser light and optical auxiliaries. Appropriate personnel protection equipment (laser protection glasses) is necessary during adjustment and operation. The line laser is a Category 2 device; operators must comply with national accident prevention regulations regarding laser radiation (e.g., UVV "Laserstrahlung" BGV B2/VBG 93 in Germany).
Material Shaking Conveyor (Specific Equipment): Works parallel with the saw drive if activated from the terminal (specific functions, page 13).
Cutting Control Unit (Optional): Inspects the cutting line. Saw blade divergence is displayed from the zero line. Two limit switches allow adjustment of personal and allowed tolerance fields.
- Limit Value I: Information and feed reducer, displayed with a message. If exceeded, the machine lifts up, switches off, and displays "cutting control limit switch II."
- If limit switch I is triggered due to saw untrue, sawing feed is reduced by 20% to extend machine operation time in "death men" operation. After 30 seconds, the cutting line is re-proofed. If the message clears, standard feed is restored. If it recurs, another 20% feed reduction occurs. If it recurs a third time without stabilization, the machine switches off the saw drive. The cutting control can be deactivated in the "Control unit" menu (page 14).
Auto - Feed - Control (AFC) (Optional): A control unit for automatic adjustment of feed and cutting velocity based on entered material width and material group. Materials are selected from the BEHRINGER material chart. After starting the saw drive, feed and blade velocity are set according to chart reference values.
- Cutting Parameter:
  - Manual Operation: Enter cutting parameters in the "Cutting data" menu (page 6).
  - Automatic Operation: For jobs in automatic operation, first go to "job input" menu (page 4) to enter data. If automatic is started with "saw off," job data is used. If started with "saw on," a message appears if "manual" or "job data" are used.
  - Set Change by Automatic Operation: For multiple sets in automatic operation, cutting length and quantity can change, but material remains the same. Control units do not accept material group or width changes during automatic set changes.
- Materials: Cutting power and blade velocity are set for various materials. Find correct material in the appendix's material chart. Enter in "Job input" menu (page 4).
- Material Width: For profile materials, the sum of wall thicknesses can be used as material width, but this results in a relatively high feed rate. The material width value for profiles should not be smaller than half the real width of the material.
Cope Device (Optional): Used for coping material during manual operation.
- Manual Cope: Adjust coping height with a ruler at the saw frame.
- Electronic Cope: Enter coping height at the operation panel (page 27, "common sawing," "coping at: ... mm"). Entering "000" means sawing through totally. A value higher than "000" means sawing until that position, then the machine switches off.

Maintenance Features:

Coolant: Regular checks and refills.
Grease Lubrication: Regular lubrication.
Gear Box: Maintenance as specified.
Hydraulic: Maintenance as specified.
Chip Brush: Regular cleaning and replacement.
Carbide Blade Guides: Regular cleaning and inspection.
Wheel Cases: Maintenance as specified.
Chip Conveyor (Specific Equipment): Regular cleaning and maintenance.
Measuring Unit (Specific Equipment): Maintenance as specified.
Change of Battery: Follow operation steps for battery replacement.
Preplacement and Cleaning of Filter Mat: Regular cleaning and replacement of filter mats.
Lubricants: Use specified lubricants.
BEHRINGER-Cool Jet Lubricate Device (Special Equipment):
- Operation: Fundamental function description, switch on/off spray cooling, calibration of spray jet, working air pressure, delivering volume, spray air volume, and proof calibration.
- Refilling Lubricant: Instructions for refilling.
- Determine Spray Stuff Consumption: Method for determining consumption.
- Choice of a Spray Stuff: Guidance on selecting appropriate spray stuff.
Central Lubrication System (Special Equipment):
- Structure and Function: Description of the system.
- Lubricant Scope: Details on lubricant usage.
- Commissioning: Steps for commissioning.
- Operation: General operation and refilling lubricant.
- Lubricant Selection: Guidance on selecting lubricants.
- Maintenance: Maintenance procedures.
- Lubricant Points and Pipe Ways: Information on lubrication points.
- Troubleshooting: Guidance for resolving issues.

Behringer HBP530A-CNC Specifications

General

Brand	Behringer
Model	HBP530A-CNC
Category	Saw
Language	English

Behringer HBP530A-CNC - User Manual

Table of Contents

Summary

Safety

Machine Hazards

Explanation of Symbols

Qualified Personnel

Proper Operation

The Workplace

Location of the Operating Instructions

Emergency Stop

Common safety regulations

Noise

Installation

Transport

Foundation

Electrical connections

Instruction for use

Rust protection paint

Coolant

Saw band choice

Operation

Description control panel

Switch on and off

Saw frame

Clamping device

Saw drive

Cutting velocity

Feed and Cutting pressure adjustment

Coolant

Sawband change

Supply Carriage

Length location stop nut (LAM)

Cutting control unit (optional equipment)

Auto - Feed - Control (AFC) (optional equipment)

Cope devise (optional equipment)

BEHRINGER Terminal BT - 41

Terminal description

Menu structure

Navigation

Function

Display - Symbolic

Function key:

Main menu (page 1)

Automatic Menu (page 2)

Cutting menu (page 5)

Diagnostic menu (page 8)

Special functions (page 12)

Setup (page 16)

Automatic operation

Reference movement

Automatic start

Automatic stop

Sawing cycle (optional equipment)

Fault messages

Safety device;guards

Wheel cover

Motor overloads

Band slip monitor

Breakage band control

Band deflection monitor (Specific equipment)

Coolant flow monitor (Specific equipment)

Coolant level monitor (Specific equipment)

Band location monitor (Specific equipment)

Protective fence (Specific equipment)

Light barrier (Specific equipment)

Maintenance

Coolant

Grease lubrication

Gear box

Hydraulic

Chip brush

Carbide blade guides

Wheel cases

Chip conveyor (Specific equipment)

Measuring unit (Specific equipment)

Change of battery

Preplacement and Cleaning of Filter Mat

Lubricants

Troubleshooting