Behringer 530a

Operating Instructions
HBP530A-CNC
BA85308
Status 46/04
Table of Contents
1
Safety
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
6
6
6
7
7
8
8
8
9
10
Transport
Foundation
Electrical connections
10
10
10
Instruction for use

3.1
3.2
3.3
Machine Hazards
Explanation of Symbols
Qualified Personnel
Proper Operation
The Workplace
Location of the Operating Instructions
Emergency Stop
Common safety regulations
Noise
Installation
2.1
2.2
2.3
11
Rust protection paint

Coolant
Saw band choice
11
11
11
Operation
12
4.1 Description control panel

4.2 Switch on and off
4.3 Saw frame
4.4 Clamping device
4.4.1 Material collet
4.4.2 Supply gripper
4.4.3 Clamping pressure
4.4.4 Bunch clamping device (Optional equipment)
4.4.5 Vertical vice (Optional equipment)
4.4.6 Gantry vise (Optional equipment)
4.5 Saw drive
4.6 Cutting velocity
4.7 Feed and Cutting pressure adjustment
4.8 Coolant
4.8.1 Swell cooling
4.8.2 Spray cooling unit (optional equipment)
4.8.3 Temperature range
4.9 Sawband change
4.10
Supply Carriage
4.11
Length location stop nut (LAM)
4.12
Chip conveyor (Optional equipment)
4.13
Roller train
4.14
Point light
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14
14
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14
14
15
15
15
16
16
16
17
17
HBP530A-CNC
Laser (optional equipment)
4.15
4.16
Material shaking conveyor (specific equipment)
4.17
Cutting control unit (optional equipment)
4.18
Auto - Feed - Control (AFC) (optional equipment)
4.18.1
Cutting parameter
4.18.2
Materials
4.18.3
Material width
4.19
Cope devise (optional equipment)
5
BEHRINGER Terminal BT - 41
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Status 46/04
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17
17
18
18
18
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19
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
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65
5.7.1.3 Material input (page 57)
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

6.1.1 Common conditions!
6.2 Automatic start
6.2.1 Basic condition
6.2.2 Start without Material
6.2.2.1 Manual material infeed
6.2.2.2 Automatic material infeed (optional equipment)
6.2.3 Start with Material
6.2.4 Inquiry cutting data (optional equipment)
6.3 Automatic stop
6.3.1 Quantity reached
6.3.2 Material end
6.3.2.1 Machine without depot
6.3.2.2 Machine with depot (optional equipment)
7
Sawing cycle (optional equipment)

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Fault messages
101
Safety device/guards
117
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
10
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
117
117
117
117
117
117
117
118
118
118
119
10.1
Coolant
10.2
Grease lubrication
10.3
Gear box
10.4
Hydraulic
10.5
Chip brush
10.6
Carbide blade guides
10.7
Wheel cases
10.8
Chip conveyor (Specific equipment)
10.9
Measuring unit (Specific equipment)
10.10 Change of battery
10.10.1 Operation steps
10.11 Preplacement and Cleaning of Filter Mat
10.12 Lubricants
119
119
119
119
120
120
120
120
120
120
121
121
122
11
Troubleshooting
123
12
Ex-operation
124
13
Appendix
124
13.1
14
Feed in relation to the current regulator position
BEHRINGER-Cool Jet Lubricate Device (Special Equipment)

14.1
Safety
14.2
Operation
14.2.1
Fundamental function description
14.2.2
Switch on and - off of the spray cooling
14.2.3
Calibration of the spray jet
14.2.4
Calibrate working air pressure
14.2.5
Calibrate delivering volume
14.2.6
Calibrate spray air volume
14.2.7
Proof calibration
14.3
Refilling lubricant
14.4
Determine the spray stuff consumption
14.5
Choice of a spray stuff
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HBP530A-CNC
Commissioning
14.6
14.6.1
Net air connection
14.7
Maintenance / maintains
14.7.1
Automatic condensate emptying
14.7.2
Manual condensate emptying
14.7.3
Sintered stainless steel filter cleaning
14.7.4
Oil container strainer cleaning
14.7.5
Sprayoil-lead/micropump bleeding
14.8
Disturbance
15
Central Lubrication System (Special Equipment)

15.1
Structure and Function
15.2
Lubricant scope
15.3
Commissioning
15.4
Operation
15.4.1
General
15.4.2
Refill Lubricant
15.5
Lubricant selection
15.6
Maintenance
15.7
Lubricant points and pipe ways
15.8
Troubleshooting
EC-Conformity Declaration
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HBP530A-CNC
BA85308
Status 46/04
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'
(Unfallverhtungsvorschriften). 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.
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1.4 Proper Operation

The sawing machine described herein is intended solely for the sawing of metal and metalrelated 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 +5C and+40C. 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.
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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
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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!
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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.
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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 BEHRINGER-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
up to 100 mm
80-150 mm
120-220 mm
from 250 mm
tooth pitch
4-6 TPI
3-4 TPI
2-3 TPI
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.
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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).
ATTENTION
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.
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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 pressurerelief 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).
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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.
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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 0C) w e 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.
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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 pushingin-shaft of the conveyor or in the machine base.
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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).
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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.
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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.
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5 BEHRINGER 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.
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5.1.1 Menu structure

Level changing with:
Within a level with:
0
1
Main menu (1)

F1-Automatic (2)
F1-Current Job (66)
F2-Job input (4)
F3F4-JOB List (49)
F5-End piece stop (51)
F2-Cutting menu (5)
F1-Cutting data (6)
F2-Time record (7)
F3-Diagnose (8)
F1-Current values (34)
F1-Sensors (9)
F2-E/A Display (10)
F3-Axis (45)
F1-Supply axis (43)
F2F3-Counter saw frame 53)
F4-Automatic Diagnos(50)
F5-Motor controller (58)
F2-PLC Cycletime (11)
F3-System info (15)
F4-Fault menu (36)
F1-Current fault (37)
F2-Fault history (38)
F5-Servise (42)
F4-Specific funct.(12)
F1-Switch functions (13)
F2-Control unit (14)
F5-Setting (16)
F1-System (17)
F1-System data (19)
F2-Material data (24)
F3-Options (22)
F4-Modem (56)
F2-Password (25)
F3-Machine constants (20)
F1-Hydraulic system (26)
F1-Parameter (18)
F2-Prop valve (23)
F2-Saw (39)
F1-Common (27)
F2-Limit values (40)
F3-Cutting behave (41)
F4-Sawblade (48)
F5-Cutting force regul.(60
F3-Clamping devise (28)
F1-Material vise (30)
F2-Supply gripper (31)
F3-Vertical vise (32)
F4-Gantry vise (33)
F4-Accessories (29)
F5-Material Transport (55)
F4-Axis (44)
F1-Infeed parameter (54)

F1-Supply axis (46)
F5-Motor controler (52)
Maschinenparameter
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F1-Parameter (35)
F2-Automatic data (47)
HBP530A-CNC
5.1.2 Navigation
Symbol Description
Cursor / Row or Field downwards / upwards
Cursor left / right
Page downwards / upwards (chart)
Begin or End of the chart (in combination with page
up/down)
Page previous / next
Boot main menu
Password input with layer display 0 3 for password
layer ; M for master password
Boot assistance page (Optional)
5.1.3 Function
Symbol Description
Switch over from ASCII- and numerical input at the
numerical field
Timer release / block
Sign change for numerical input
Delete input
Escape job (ESC)
Job confirm / finish (OK)
Activate / switch over to filters
Date/time take over
Data save / boot
Value increase / degrease
Restart system (Warmstart/Coldstart)
Transmit configuration
Loading material diagram
Copy / Insert
Profile selection
Setdata fast programming with entry in the JOB - List
Function selection f.e. stop after job-end or end piece
sawing
Function dynamical in- out- sawing activate respectively
deactivate
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Start a function
Deleting every actual quantities in the jobs and set start
indicator in the job list to position1.
5.1.4 Display - Symbolic

Symbol Description
Message, Interruption active
Function Data save is active
Fault while loading/saving data
Sawplate Sintered hard carbide (HM) and Bimetal (BI)
Output signal OFF and ON
Automatic OFF after set end
Function end piece sawing
Row marking e.g. for start set in JOB List
Dynamical in- out sawing is active
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5.1.5 Function key:

SA off
With this key, the saw drive (SA)
is switched off.
SA on
With this key, the saw drive (SA)
is switched on.
Hydraulic on
With this key, the hydraulic pump
is switched on/off.
Fast velocity
With this key in the manual
operation the fast movement for
the NG plus respectively minus
are executed.
SR lifting
With this key the saw frame (SR)
is lifted.
Automatic on
With this key the reference
movement respectively the
automatic operation are started.
SR lowering
With this key, the saw frame (SR)
is lowered.
MZ open
With this key, the material vise
(MZ) is opened.
Vertical Clamp open

With this key, the vertical clamp
(VS) is opened.
MZ clamp
With this key, the material vise
(MZ) is clamped.
Vertical vise clamping

With this key, the vertical clamp
(VS) is clamped.
NG plus
With this key the supply gripper
are moved to the plus direction.
NG open
With this key, the Feeding Gripper
(NG) is opened.
NG minus
With this key the supply gripper
are moved to the minus direction.
NG clamping
With this key, the Feeding Gripper
(NG) is clamped.
Portal Clamp open

With this key, the Portal vise (PS)
is opened.
Portal Clamp clamping

With this key, the Portal Clamp
(PS) is clamped.
Reset
With this key, fault messages are
cleared.
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5.2 Main menu (page 1)

From the main menu, several sub menus can be accessed. From the sub menus it is
always possible to return to the main menu by pressing the button
. Within a sub menu
it is possible to scroll with the arrow keys located below the function keys. The arrow keys
will scroll forward and back respectively. In the main menu it is possible to access the sub
menus by pressing the corresponding Function key or by entering the page number and
confirming the selection with the return key. With this key
it is possible to jump one
menu layer backward. With the arrow keys below the F3 or the F6 key it is possible to
scroll between the various menus.
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5.3 Automatic Menu (page 2)

Main Menu F1 Automatic menu
From this sub menu it is possible to access further menus used for the automatic process.
Before running the machine in automatic, at least one job has to be programmed and it
must be saved to the job list.
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5.3.1 Latest state of data (page 66)

Main Menu F1 Automatic menu F1 latest state of data
Description of the single chapters:

Job data
Displaying the nominal- and actual data of the current job during the automatic procedure.
Job Nr.:
Displays the current running order (Job).
Length :
Displays the set cutting length.
Theoretical amount:
Displays the number of pieces required.
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Actual amount :
Displays the number of pieces completed.
Cutting data
Displaying the actual data and entering the nominal data for blade velocity and the sawing
feed during the automatic procedure.
Displaying the stresses for the saw drive.
The function keys left and right of the monitor are provided with the following functions.
Function key F1: Plus

Blade velocity fast
Function key F2: Minus

Blade velocity slow
Or Direct input
Function key F4: Plus

Sawing feed fast
Function key F5: Minus

Sawing feed slowly
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Or Direct input
Cutting control
5.3.1.1.1 Displaying and entering the limit values.
As long as the machine is equipped with a cutting control unit the divergences are
described and it is possible to change the limit values.
Tool thrust regulation

Displaying and entering the regulating step.
If the sawing machine is equipped with a tool thrust regulation unit then the pressure at the
saw blade are displayed. Also it is possible to change the regulation step (1-9).
Regulation step see page 60 (cutting force regulation).
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5.3.2 Record Data (page 4)

Main Menu F1 Automatic menu F2 Record data
In the Record Data menu, the length and target quantity combinations are programmed
The function keys to the left and right of the monitor provides the following functions
Function key F1: Quick programming key.

By pressing the F1 key
the currently entered job data is saved and the job is copied
into the job list. It is then possible to start the automatic without accessing another menu.
The automatic function ceases when the number of pieces to be cut is reached or the
Automatic cycle is interrupted.
Function key F2: Job data saving.

the currently entered job data is saved. If this menu is left
without saving the entered job data, the entered data is not stored.
Function key F4: Copy /Insert

once, the current job data is copied into an intermediate
memory. By pressing the key a second time, the job data is inserted into the active
memory.
Function key F5: Material chart (optional)

Pressing the F5 key
accesses the material chart. From the chart, it is possible to
highlight a material and select it as the material to be cut by use of the return key. (See the
chapter Material Chart).
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Function key F6: Job data with default, overwrite job data.
the highlighted field is erased and the original data restored.
The saving of the default job data is explained in the chapter system data page 19.
Job Nr.:
Selection of the job number to compile an order.
Material (optional):
Displays the selected material. The material is selected from the material chart.
Bars:
Enter the number or bars per layer.
Layers:
Enter the number of layers.
Trim cut:
Enter the desired trim cut length. (If a trim cut length of 0 is entered, no trim cut is
performed).
Width (optional):
Enter the material width.
Length:
Enter the desired cutting length. Enter the length with no decimal point to 4 places.
(example: entering 5000 equals 0.5, entering 50000 equals 5.0)
Nominal quantity:
Enter the number of parts desired.
Actual quantity:
Displays the completed number of parts. To reset the actual quantity, press the reset key .
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5.3.3 Record data
Main menu
4 (direct to page 4 Record data)
F1 Automatic menu
F2 Input batch
data
Input Job number JOB: __
Input Poles number of Layers Layers: __
Input Poles number of Pieces Stck: __
Input Trimcut 10,00mm (Input without decimal point)
without AFC
with AFC
Input width of material ___mm
Input length of material Lenght ___mm (Input without decimal point )
Input number of pieces Pieces Nominal ___
By pressing the F2 key, the programmed job data is saved. If the screen is
left without saving, the changes are not saved (not necessary if F1 quick
programming key is used).
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By pressing the key F1 quick programming key, the currently entered job
data is saved and the job is copied into the job list. It is then possible to start
the automatic cycle without calling up another menu. The automatic function
stops after the job is finished.
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5.3.4 Job list (page 49)

Main Menu F1 Automatic menu F4 Job list
With that chart it is possible to machine several jobs on after each other automatically.
These is an advantage if several cuttings are to saw with an different length from the same
bar.
Function key F1: row marker upwards (optional).

the row marker is moved one row upwards. If the automatic
cycle is started, the cycle will start with the job highlighted by the row marker.
Function key F2: row marker downwards (optional).

the row marker is moved one row downwards. If the
automatic cycle is started, the cycle will start with the job highlighted by the row marker.
Function key F3: Password Input.

the page password input screen is accessed.
Function key F4: Job Reset.

By pressing the key F4
are deleted in every job the actual quantity and the row
marking of the job list are moved to position 1. This function is used to repeat the last
automatic operation.
Function key F5: Delete job list.

the total job list will be deleted.
Function key F6: Select function

the function column.
the stop function
or cutting a remnant piece
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The stop symbol means that, after the marked job is completed, the automatic
cycle will be stopped.
The remnant piece function means that a remnant piece can be clamped in the feed
gripper without the material end switch being actuated. The material has to be moved
under the saw blade, the saw blade and the automatic cycle has to be started. The
machine cuts the material until the programmed piece number is reached or the feeding
gripper has reached the front limit position.
.
The job list determines the sequence of the jobs. The row marker marks the first job to
be started. When a job is completed, the row marker moves one row down and that job
will be processed. If a stop is set in the highlighted row the automatic operation will cease
when this job is completed. If the next job has 0 set for the length and/or pieces required,
the job will act as a stop and the automatic cycle will be stopped.
5.3.5 Job list
Main menu
49
(direct to page 4 Record data)
F1 Automatic menu
F4 Job list
Input Job number in the field JOB
Making of the Job beginning. F1

the row marker is moved one row upwards. If
the automatic is started, it will be started with the job which is written behind the row
marking.
Marking of the Job stop. By pressing the key F6 a stop will be set behind the
marked row (black coloured). The stop symbol means that after the job which is
marked with a stop is machined the automatic cycle will be stop
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5.3.6 End piece stop (page 51)

Main menu F1 Automatic menu F5 End piece stop
Specific equipment
In this menu it is possible to position or to change the end piece Stop.
Proof parameter : this input is for changing the distance between rear edge sawband
until end piece stop. This cutting parameter is determined on Behringer side.
Nominal position : here is to enter the wanted nominal length. After the input is finished the
end piece stop moves to the new position and it is possible to saw a cutting. (Cutting is
pushed against the end piece stop, clamped and sawed).
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5.4 Cutting menu (page 5)

Main menu F2 Cutting menu
From this menu it is possible to access the sub menus which are used for the sawing
process.
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5.4.1 Cutting data (page 6)

Main menu F2 Cutting menu F1 Cutting data
Function key F5: Increase Value .

the value of the active input field will be increased by 1.
Function key F6: Decrease value.

the value of the active input field will be decreased by 1.
The values can also entered by the numerical keys and saved with return.
Function key F4: Dynamical in- and out sawing (optional).

the function dynamical in- and out sawing is activated
respectively deactivated. If the function is active the symbol
is displayed on the top
screen frame. With the function dynamic in- out- sawing the band velocity and feed
velocity for the sawing in distance respectively sawing out distance are reduced with the
preselected percentage parameter. In the chapter cutting conduct 6.7.3.3.3 (picture mask
page 41) the settings are more accurate described.
The material field and the feed field are optional.
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5.4.2 Cutting data
Main menu
6 (direct to page 4 Record data)
F2 Cutting data
F1 Cutting data
without AFC
with AFC
Adjustments automatic
finished
Input sawblade speed V-Blade Nominal: __ m/min
Input Feed rate Nominal: __ mm/min
finished
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5.4.3 Time record (page 7)

Main menu F2 Cutting menu F2 Time record

Pressing the F3 key
password input screen is accessed.
Function key F6: Delete Lifetime.

the lifetime will be reset.
Operation counter
In the runtime counter field, the operation time of the hydraulic pump and the saw drive are
displayed.
Cutting Time
In the cutting time field, the actual time of the current cut and the time for the last cut is
displayed. The cutting time is measured from when the Material Height sensor contacts
the material until the lower limit switch is reached.
Lifetime:
In the lifetime field, the length of time the saw blade has been in use is displayed. In order
for the blade life timer to be accurate, the lifetime must be reset at every blade change by
pressing the function key F6.
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5.5 Diagnostic menu (page 8)

Main menu F3 Diagnostic menu
From this menu it is possible to access several diagnostic sub menus.
5.5.1 Actual values (page 34)

Main menu F3 Diagnostic menu F1 Actual value
From this submenu it is possible to change over into the several diagnostic menus.
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5.5.1.1 Sensors (page 9)

Main menu F3 Diagnostic menu F1 Actual value F1 Sensors
In the diagnostic Sensor menu, the status of the cutting control unit and the voltages of
several analogue sensors is displayed.
Sensor voltage:
Used in the calibration of the cutting control sensor. There should be a voltage of 5.00 V if
the blade guide are clamped.
Cut deviation:
Shows the deviation from the theoretical line during the sawing process. It can only show
the deviation of the blade measured at the sensor. The deviation inside of the material can
not measured and therefore no analyse is possible.
If the cutting control shuts off the machine, deviation value is saved until the restart.
Tool thrust (Cutting Pressure) sensor (optional)
Displays the value of the tool thrust sensor (cutting pressure).
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5.5.1.2 Digital I/O (page 10)

Main menu F3 Diagnostic menu F1 Actual value F2 Digital I/O
In this menu, the individual states of the digital inputs and outputs are displayed. In the first
line, the module being monitored is shown.
BT 41 DI
= Digital inputs of the terminal (BT41).
BT 41 DO
= Digital outputs of the terminal (BT 41).
BT 41/1 DI138
= Digital inputs of the supplementary terminal (optional).
DM 465/EA2/DI = Digital inputs of the module EA2 (Module type DM465).
DM 465/EA2/DO
= Digital outputs of the module EA2 (Module type DM465).
DI 439/E3
= Digital inputs of the module E3 (Module type DI439).
DO 435/A4
= Digital outputs of the module A4 (Module type DO435).
DO 435/A5
= Digital outputs of the module A5 (Module type DO435).
DM 435/EA10/DI
= Digital inputs of the module EA10 (Module type DM435).
DM 435/EA10/DO = Digital outputs of the module EA10 (Module type DM435).
DM 435/EA20/DI
= Digital inputs of the module EA20 (Module type DM435).
DM 435/EA20/DO = Digital outputs of the module EA20 (Module type DM435).
In the left column, a brief description identifying the sensor is given. The middle column
indicates the number of the input/output respectively. The right column indicates the
current state of the input/output. The symbol means the input/output is switched off.
The symbol means the input/output is switched on.
Function key F5: change over to the next module.

Pressing the F5 key
will switch the display the next module.
Function key F6: change over to the previous module.

Pressing the F6 key
will switch the display to the previous module.
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5.5.1.3 Axis Diagnosis (page 45)

Main menu F3 Diagnostic menu F1 Actual values F3 Axis
From this subdistributor menu it is possible to change over into the several diagnosis
menus of the axis.
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5.5.1.3.1 Infeet axis (page 43)

Main menu F3 Diagnostic menu F1 Actual values F3 Axis F1 Infeet axis

Pressing the key F3
will access password input screen.
Actual position
Indicates the current position of the feeding gripper. If the axis is not referenced, 0.00 mm
is displayed as the actual position.
Theoretical position
Indicates the targeted position of the feeding gripper.
Deviation
Shows the last deviation of the positioning. If the feeding gripper has moved too far, the
deviation is positive. If the feeding gripper has stopped short of its target, the deviation is
negative.
State register
From the status bits, it is possible to monitor the state of the axis module. The individual
bits have the following meaning.
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
: Status of the reference impulse (rotary indicator).

: Status of the reference release signal.
: Status of the rotary indicator track B.
: Status of the rotary indicator track A.
: Output status of the Comparators.
: Consume voltage > 18V, Outputs OK.
: changing after every referencation the sate.
: Axle is referenced.
The bits 8-15 are a currently not in use.

Test Positioning
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This value is needed for commissioning purposes.
5.5.1.3.2 Counter saw frame (page 53)

Main menu F3 Diagnostic menu F1 Actual value F3 Axis F3 Counter saw frame
Actual position
Here it is displayed the actual position of the saw frame. If the axis is not reference, then 0
mm is shown in the actual position.
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5.5.1.4 Automatic diagnostic (page 50)

Main menu F3 Diagnostic menu F1 Actual value F4 Automatic diagnostic
Automatic Step counter machine

Here it is shown the current operating automatic operating step of the machine.
This information is helpfully for a fault research.
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5.5.1.5 Motor controller diagnosis (pagee 58)

Main menu F3 Diagnosis menu F1 Actual value F5 Motor controller diagnosis
In this mask are displayed the current motor data of the selected controller.
Function key F4: Reference movement Servo start. (Specific equipment)

the reference movement for the servo of the sawframe is
started. This function is only used for substitute the servo controller or servo motor.
Function key F5: change over to the next motor controller.

it is switched to the mask of next motor controller. To take over
the function the Enter key is to actuate.
Function key F6: change over to the previous motor controller.

it is switched back to the mask of previous motor controller. To
take over the function the Enter key is to actuate..
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5.5.2 Task Runtimes (page 11)

Main menu F3 Diagnostic menu F2 CPU operation times
In the menu , the operation times of the CPU are stored.
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5.5.3 System Inf. (page 15)

Main menu F3 Diagnostic menu F3 System Info
In this menu it is possible to read several data of the machine.
Machine number
Here it is displayed the machine number.
Electric print
Here it is displayed the drawing number of the electric print.
Hydraulic print
Here it is displayed the drawing number of the hydraulic print.
Program
Here it is displayed the program number.
Program version
Here it is displayed the program-version.
Operating system
Here it is displayed the number of the operating system from the plc.
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5.5.4 Alarm System (page 36)

Main menu F3 Diagnostic menu F4 Alarm System
From this submenu distributor it is possible to change over into the several menus of the
alarm systems.
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5.5.4.1 Actual Alarm (page 37)

Main menu F3 Diagnostic menu F4 Alarm System F4 Actual Alarms
Fault messages are indicated by the flashing fault diode and the flashing fault reset key.
The fault messages are cleared by pressing the fault reset key. Clearing faults is possible
from every screen.
Function key F5: Change to the previous fault.

Pressing the F5 key
moves the cursor to the previous fault message.
Function key F6: Change to the next fault.

Pressing the F6 key
moves the cursor to the next fault message.
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5.5.4.2 Alarm History (page 38)

Main menu F3 Diagnostic menu F4 Alarm System F2 Alarm History
The last 40 fault messages are saved with the date and time. A new fault be added to the
top of the list and the last fault will be deleted.
Function key F5: Change to the previous fault.

Pressing the F5 key
will move the cursor to the previous fault message.
Function key F6: Change to the next fault.

Pressing the F6 key
will move the cursor to the next fault message.
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5.5.5 Service Menu (page 42)

Main menu F3 Diagnostic menu F5 Service
From the servise menu, it is possible to reset the CPU by a warm or cold restart.

Pressing the F3 key
the password input screen is accessed.
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5.6 Special functions (page 12)

Main menu F4 Special functions
From this menu it is possible to change to several specific function menus.
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5.6.1 Switching functions (page 13)

Main menu F4 Special functions F1 Switching functions
Function key F2: Save Switch function.

Pressing the F2 key
saves the switch settings. If the screen is left without saving, the
changes are not saved.

Pressing the F3 key
the password input screen is accessed.
Function key F5: Modify Switch functions.

Pressing the F5 key
modifies the highlighted switch function.

Pressing the F6 key
Coolant
Coolant: Off
means, sawing without coolant
Coolant: Water
means, the pump runs together with the saw drive.
Coolant : Spray
means the spray cooling unit will be used. (Optional)
Coolant: Water continuous

Coolant: Spray continuous
means the pump runs in the continuous operation.

means the spray cooling runs in the continuous
operation. (Optional)
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Chip conveyor (Specific equipment)

Chip conveyor : On
means the chip conveyor runs with the saw drive.
Chip conveyor : Cycle
Chip conveyor : Continuos
means the chip conveyor runs with the saw drive in the
cycle operation. The run/rest times are set in the
machine constants.
means the chip conveyor runs continuously.
Material vise opening before lifting saw frame

MZ open before SR lifting : Off means after every automatic cut, the saw frame lifts above
the material before the material vise opens.
MZ open before SR lifting: On means after every automatic cut, the material vise opens
before the saw frame lifts up over the material.
Vertical vise opens before horizontal vise
Vert. before Horiz. opens : Off means the horizontal clamp(s) opens before the vertical
clamps in the automatic operation.
Vert. before Horiz. opens : On
Saw drive
Saw drive: Normal
means the vertical clamp(s) opens before the horizontal

clamps in the automatic operation.
means the saw drive is switched off between cuts in the

automatic mode.
means the saw drive runs continuously during the
automatic mode. Note: This function is only active during
a single stroke.
Saw drive: Continuous
Cutting channel extension (Specific equipment)

Cutting channel extension : Off
means , the function is switched off.
Cutting channel extension : On
means, the supply carriage is moved backward after

every automatical step about the cutting channel,
that the sawband is to lift up undisturbed
Vertical clamp (Specific equipment)

Activates/deactivates the vertical clamp.
Portal Clamp (Specific equipment)
Activates/deactivates the Portal clamp.
Supply carriage back before sawing
Off means, the supply carriage starts a backstroke for
bringing in new material after it was sawed through.
On means, the supply carriage starts a backstroke for
binging in new material before the material was sawed
through.
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Trim cut manual take out (Optional equipment))

Trim cut manual take out: off means the function is switched off.
Manual take out: only first cut
means, if during a automatic operation a cutting is

sawed then the automatic cycle is interrupted by the
machine after the procedure is finished. Now it is
possible to take out the cutting manually. If the flashing
key Reset is pressed then the automatic operation is
continued.
Manual take out: all cuttings
means, during the automatic operation interrupts the

sawing machine the automatic cycle after every finished
cut. Now it is possible to take out the cutting manually.
If the flashing key Reset is pressed then the automatic
operation is continued.
Long residual cutting (specific equipment)

Long residual cutting: Off
means, that the residual cutting for material end is
clamped as short as possible.
Long residual cutting: On
means, that the residual cutting for material end is

clamped longer for safety reasons.
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5.6.2 Control devise (page 14)

Main menu F4 Special functions F2 Control device
This menu is used to switch off existing control/monitoring units, should the unit
malfunction. All existing control/monitoring units will be activated when the main power is
turned on..
Function key F2: Switch function saving.

Pressing the F2 key
, the set switch functions are saved. If this screen is left without
saving the changes, switch functions will not be saved.

Pressing the F3 key
accesses the password input screen.

Pressing the F5 key

Pressing the F6 key
Cutting control unit (Optional equipment)

This switch turns on/off the cutting control unit.
Blade deflection monitor (Optional equipment))
This switch turn on/off the blade deflection monitor.
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Blade slip monitor

This switch turns on/off the blade slip monitor.
Coolant control (Optional equipment))
This switch turns on/off the coolant control monitor.
Spray cooling control (Optional equipment))
This switch turns on/off the spray cooling unit.
Tool thrust control unit (Optional equipment))
This switch turns on/off the tool thrust control unit.
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5.7 Setup (page 16)

Main menu F 5 Setup
From this menu it is possible to access several settings and machine constant menus.
5.7.1 System (page 17)

Main menu F5 Settings F1 System
From this subdistributor menu it is possible to change over into the several system menus.
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5.7.1.1 System data (page 19)

Main menu F5 Settings F1 System F1 System data
Function key F2: Saving System data

Pressing the F2 key
saves the entered system data. If the screen is left without
saving, the changes are not saved.

Pressing the F3 key
Function key F4: Change value.

Pressing the F4 key
highlighted selection.
increases the set value or scrolls through the options for the
Function key F5: Change value.

Pressing the F5 key
selection.
decreases the set or scrolls through the options for the highlight
Function key F6: Take over time.

Pressing the F6 key allows the time to be set.
Language
Selects between the various languages.
Measure unit
Selects the measurement units (mm or inch).
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Format
Selects the display format for the time.
Contrast
Sets the contrast for the display.
Time
Sets the time
Date
Sets the date.
Material chart (Option)
Selects the material chart.
Default set
Here it is determined the job number which job is used as a macro with presetted job data.
During the job erection at the screen page 4 the presetted job data are to request with the
function key F6. If the entered parameter is confirmed with the return key, then the
corresponding default set (presetted set) is saved. If in the job input menu is actuated the
delete key then the selected job is filled out with the default data.
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5.7.1.2 Material list (page 24)

Main menu F5 Settings F1 System F2 Material list
In the menu material chart are 255 materials with cutting data stored. The cutting data are
determined by company Behringer. It is possible for the customer to change or optimise
this parameter. With the help of the function keys it is possible to search for a material and
select it. At the beneath monitor screen are displayed the feed and the blade velocity of
the current selected material corresponding to the material width.
Function key F1: Material changing and adding.

them as a new material..
it is possible to change the current selected material or to save
Function key F2: Search function.

Pressing the F2 key
activates the search function. By entering a ID number the
corresponding material can be selected. Pressing the F2 key a second time changes the
search function to the material number. Entering a material number selects the material.
Pressing the F2 key a third time, the search function is changed to the description column.
Pressing the F4 key will change over to the ASCII input and search for material names.
Function key F3: Going to the start or end of a list.

Pressing the F3 key
and then the F5 key
down), will move to the start or end of the list.
(page up), or the F6 key
(page
Function key F4: Switch to keyboard .

Pressing the F4 key
changes between ASCII and numerical input at the numerical
block. This is necessary for the search function
Function key F5: Paging downwards.

Pressing the F5 key
will page down the list.

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Function key F6: Paging upwards.

Pressing the F6 key
will page up the list.
5.7.1.3 Material input (page 57)
In the menu material input it is possible to change the selected material and save it, or it is
possible to add it as a new material at the end of the material chart.
To create a new material name at first it is to select an applicable existing material from
the chart. This one is to change in the necessary parameters and then it is to press F1.
The changed material is then add to the end of the material chart.
Function key F1: Duplicate material and add to the material end.
it is possible to duplicate the selected material to the chart
end. This is only possible during an active password level 3.
Function key F2: Save data.

the entered data are saved and taken over. This is only
possible during an active password level 3. If the menu is left without saving the data will
be lost.

it is changed over to the page password input.
Function key F4: Change the material name.

and an active password level 3 it is possible to change the
material name. The keyboards operates as an telephone keyboard.
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Function key F5: Loading the Behringer material chart.

and an active password level M it is possible to boot the
Behringer material chart. Changes different to the chart are overwrite. Self added materials
are unvaried.
5.7.1.4 Modem Settings (page 56).

Main menu F5 Settings F1 System F4 Modem Settings
The entering of the initialisation and of the recall number occurs with the initial- and
numerical key. The keyboard operates as for a mobile telephone. By pressing the
corresponding numerical key several times it is to change between the different signs. The
comma, which is to use for the connection of a telephone set is to search for the ? key. To
change the settings of this page the pass word level three has to be active. With the
function key F5 and F6 it is to select between the initialisation and the recall number input
5.7.1.4.1 Initialisation
The set AT- commands have the following meaning.
X0
M0
E0
S0=1
The modem answers CONNECT to BT41, as soon as a connection exists to

another modem.
The loud speaker of the modem is switched off.
The modem answers no echo back to the BT41.
The modem lifts after the first jingle automatically.
Further AT commands could read in the corresponding modem manual.

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5.7.1.4.2 Recall number

If at the modem is installed a telephone line , then the recall number will looks like .
e.g. National: 07266207226

e.g. International : 00497266207226
If the modem is connected to a telephone set, then the dialling is to start of the proper
telephone number with a exchange claim, interrupted by a short break.
e.g. National: 0,07266207226
e.g. International: 0,00497266207226
By dialling the 0 the exchange line is select (only for common telephone set). The point
effects a dialling break from 3 seconds.
For especial telephone sets it is also possible to have a different sing for the exchange
line. The sign has to ask for.
5.7.1.4.3 Start modem operation at BT 41

To create a modem connection between the BT41 and the telemaintenance PC, it is at the
BT41 to actuate the key F4 at manual page 56 once through after every net switch on.
Unaffected the modem has to be switched on and precise connected.
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5.7.2 Password (page 25)

Main menu F5 Settings F2 Password
It existing 4 different password levels. The password level 1 is the lowest password level.
The password level 4, the mast password, have the highest priority.
The priority of the password levels are ascending.
Password level 1
The password level is provided for the machine operator. With it, it is possible to set
several machine settings. With the higher password levels it is also possible to do this.
Password level 2
This password level is not classified to a specific input.
With this level it is also possible to do the settings from the level 1
Password level 3
This password level is classified for the service.
With this password level it is possible to set machine parameter setting, which are only to
do by authorised stuff and the service.
With the higher password level (4) ,the master password, it is also possible to do the
same.
Password level 4 master password (M)
This password level is exclusive reserved for the Behringer customer service.
With this password level it is possible to do all the machine and parameter settings.
Settings in this password level are exclusive reserved for authorised service stuff.
Basic settings password.
The basic settings of the password are to request by Behringer.
The passwords of the levels 1, level 2, and level 3 are to change with the password level 3
and password level 4 (master password). The passwords of the levels 1 to 3 are displayed
by entering the password level 3 or the master password.
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Function key F2: Password save.

the entered passwords are saved and taken over. If it is
abandoned the mask without saving then the changed passwords are reject.
Overview BT41 Screen display Password level

Screen display
Page
Page 13
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Page 15
Page 18
Page 19
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Page 23
Page 27
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Page 30
Page 31
Page 32
Page 33
Page 35
Page 40
Page 41
Page 42
Page 43
Page 47
Page 48
Page 49
Page 51
Page 52
Page 54
Page 56
Page 57
Page 58
Page 60
Password level
1
Not necessary
X
X
Not necessary
Password level
2
Not necessary
X
Password level
3
Not necessary
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Not necessary
X
X
Not necessary
X
X
X
X
X
X
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Password level 4
Masterpassword
Not necessary
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Not necessary
X
X
X
X
X
X
X
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5.7.3 Machine Constant (page 20)

Main menu F5 Settings F3 Machine constant
From this submenu distributor it is possible to change over into the several machine
constants menus.
5.7.3.1 Hydraulic system (page 26)

Main menu F5 Settings F3 Machine constants F1 Hydraulic system
From this submenu distributor it is possible to change over into the several hydraulic
system menus.
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5.7.3.1.1 Hydraulic values (page 18)

Main menu F5 Settings F3 Machine constants F1 Hydraulic system F1
Hydraulic values
Function key F2: Saving Data.

Pressing the F2 key
saves the entered data. If the screen is left without saving, the
changes are not stored.

Pressing the F3 key
.
Off time
Sets the timer of the hydraulic pump. If the hydraulics are not needed for that time period,
the hydraulic pump will be switched off automatically.
Off time for saw blade change
Sets a separate timer for the hydraulic pump during a blade change.
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5.7.3.2 Setting of H&L current regulator (optional) (page 23)

Main menu F5 Settings F3 Machine constants F1 Hydraulic system F2
Proportional valve
In this menu it is possible to set the prop valve current regulator which control the saw
feed. Only machines with Auto Feed Control or feed remote setting are equipped with a
prop current regulator. Every machine is equipped with a manual current regulator and this
menu page is not accessible..
5.7.3.2.1 Setting instruction
Saw feed switched on!

Attention the measurements are only to do with warmed up
hydraulic oil. Therefore the feed has to run for approximately
one hour!!
In the menu Machine constant propvalve (page 23) by actuating the key
entering
the password level (Level 3) and afterwards switching ON the feed balancing with
the keys F5
or F6
In the nominal field are then to enter the following voltages (see below), the
corresponding feed parameter measured and to write down.
Voltage 1
Voltage 2
Voltage 3
Voltage 4
Voltage 5
Voltage 5
Voltage 6
= 0.5V
= 2V
= 3V
= 4V
= 5V
= 7V
= 9V
= feed parameter 1 (P1)

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Now are to enter the following inputs in the chart. In the row P0 are to enter a voltage
of 0V and a feed from 0.0 mm/min. In the row P1-P9 are to enter the allowed voltages
and the corresponding feeds. Unnecessary rows are to enter with a 0 (see picture).
At the end the inputs are to save with the key F2
After the settings are finished the feed balancing has to switched off again. Otherwise the
valve could not work!!
5.7.3.3 Saw Menu (page 39)

Main menu F5 Settings F3 Machine constants F2 Saw
From this subdistributor menu it is possible to change over into the several saw menus.
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5.7.3.3.1 Saw General (page 27).

Main menu F5 Settings F3 Machine constants F2 Saw F1 Saw General

Pressing the F2 key

Pressing the F3 key
Saw bow over material

Sets the time the saw frame will continue to rise after the material height sensor lifts off the
material when in the Automatic mode.
Blade slip monitor:
Set the impulse sequence timer of the blade slip monitor.
To adjust the timer, the blade speed should be set to minimum and the time decreased
until the blade slip monitor generates a fault. Then increase the time slightly (standard time
approx. 2.5 sec.).
Maximum feed (optional)
Sets the maximum possible feed.
Minimum V-Blade
Sets the minimum blade speed.
Maximum V-Blade
Sets the maximum blade speed.
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Factor material chart

Factor to optimise the cutting power from the material list for AFC.
Scale saw drive
Parameter to scale the analogue signal for the frequency converter of the saw drive.
Sawing machine slowly start
Time limit for the saw drive that it starts during the switch on slowly (approx. 3s) and
afterwards accelerates to the nominal velocity.
This is important for sawing machines, which are equipped with guiding arms settings.
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5.7.3.3.2 Saw Thresholds (page 40).

Main menu F5 Settings F3 Machine constants F2 Saw F2 Thresholds

Pressing the F2 key

Pressing the F3 key
Cut control unit delay time (optional)

The cut control monitor delays the set time after beginning a cut before activating.
Cut control unit limit value 1 (optional)
Sets the first threshold of the cut control unit.
Exceeding the first threshold limit will be indicated by a message on the screen. If the
machine is equipped with Auto Feed Control (AFC) the feed rate will also be reduced
when the first threshold limit is reached.
Cut control unit limit value 2 (optional)
Sets the second (maximum) threshold limit of the cut control unit.
Exceeding the second threshold limit will switch off the saw drive and the red interruption
lamp will be flashing.
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5.7.3.3.3 Cutting conduct (page 41).

Main menu F5 Settings F3 Machine constants F2 Saw F3 Cutting conduct

Pressing the F2 key

Pressing the F3 key
Saw blade change reduce blade velocity (optional)

Sets the percentage the blade velocity will be reduced after a saw blade replacement.
Saw blade change reduce feed (optional)
Sets the percentage the feed will be reduced after a saw blade replacement.
Saw blade change blade break-in in time (optional)
Sets the break-in time for a new saw blade.
In- and out sawing
Band velocity reduction (optional)
Here it is to set how many percent the band velocity is to reduce during dynamical sawing.
Feed reduction (optional)
Here it is to set how many percent the feed is to reduce during dynamical sawing.
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Sawing in distance (optional)

Here it is to enter about which distance it is to saw in reduced mode until the feed and the
band velocity will be increased about 100%.
Sawing out distance (optional)
Here it is to enter about which distance it is to saw in reduced mode until the material is
sawed complete.
Cutting end position (optional)
Here it is to enter the position if the sawframe is located in its lowest position (complete
sawing).
Time cycle (optional)
Here it is to enter after which cycle the increasing starts.
Dynamical in- and out sawing
By pressing the key F4 (picture mask page 6) the function dynamical in- and out sawing is
activated respectively deactivated.
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5.7.3.3.4 Saw blades (page 48).

Main menu F5 Settings F3 Machine constants F2 Saw F4 Saw bands

Pressing the F2 key
changes data are not stored.

Pressing the F3 key
Function key F4: Saw blade selection.

Pressing the F4 key selects the type of blade being used,
(carbide) or
(bimetal)
Adjust cut width (carbide)

Sets the blade kerf (width) when using carbide blades The blade kerf can be determined
by cutting a slot into solid material and measuring the width of the cut.
Adjust cut width (bimetal)
Sets the blade kerf (width) when using bimetal blades The blade kerf can be determined
by cutting a slot into solid material and measuring the width of the cut.
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5.7.3.3.5 Cutting force regulation (Page 60).

Main menu F5 Settings F3 Machine constants F2 Sawing machine F5 Cutting
force regulation
Function key F2: Data storing.

the entered data are stored and taken over. If the menu is left
without storing then the changed system data are reject.
Function key F3: Password input.

the menu password input occurs.
In this menu are to enter the parameter for the regulation unit (1-9). These data are only to
change from a professional stuff because this input can course to faulty functions.
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5.7.3.4 Clamping devices (page 28)

Main menu F5 Settings F3 Machine constants F3 Clamping devices
From this subdistributor menu it is possible to change over into the several clamping
devices menus.
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5.7.3.4.1 Material clamp (page 30).

Main menu F5 Settings F3 Machine constants F3 Clamping devices F1 Material
clamp

Pressing the F2 key

Pressing the F3 key
Material Clamp
Adjusts the various timers used to control the opening and closing of the material clamp in
automatic operation
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5.7.3.4.2 Feed gripper (page 31).

Main menu F5 Settings F3 Machine constants F3 Clamping devices F2 Feed
gripper

Pressing the F2 key

Pressing the F3 key
Feed Gripper
Adjusts the various timers used to control the opening and closing of the Feed Gripper
clamp in automatic operation
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5.7.3.4.3 Vertical clamp (page 32).

Main menu F5 Settings F3 Machine constants F3 Clamping devices F3 Vertical
clamp

Pressing the F2 key

Pressing the F3 key
Vertical Clamp
Adjusts the various timers used to control the opening and closing of the vertical clamp in
automatic operation
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5.7.3.4.4 Portal clamp (page 33).

Main menu F5 Settings F3 Machine constants F3 Clamping devices F4 Portal
clamp

Pressing the F2 key

Pressing the F3 key
Portal Clamp
Adjusts the various timers used to control the opening and closing of the portal clamp in
automatic operation
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5.7.3.5 Paraphernalia (page 29).

Main menu F5 Settings F3 Machine constants F4 Paraphernalia

Pressing the F2 key
.

Pressing the F3 key
accesses the password input screen..
Centralized lubrication (optional)

Adjust the timers for the centralized lubrication system.
Swarf Conveyor
Adjusts the timers for the swarf (chip) conveyor
Coolant Return Pump (optional)
Adjusts the timers for the coolant return pump.
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5.7.3.6 Material Transport (page 55).

Main menu F5 Settings F3 Machine constants F5 Material Transport
From this subdistributor menu it is possible to change over into the several material
transport menus.
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5.7.3.6.1 Infeed Parameter (page 54).

Main menu F5 Settings F3 Machine constants F5 Material Transport
F1 Infeed Parameter
Function key F2: Data saving.

the entered data are saved and taken over. If it left the menu
without saving the data then the system data are lost.

it will come the page password input.
In this menu are entered the times for the automatical incoming material.
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5.7.4 Axis Menu (page 44)

Main menu F5 Settings F4 Axis
From this subdistributor menu it is possible to change over into the several axis menus.
5.7.4.1 Infeed axis (page 46)

Main menu F5 Settings F4 Axis F1 Infeed axis
From this subdistributor menu it is possible to change over into the infeed axis menus.
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5.7.4.1.1 Infeed parameters (page 35).

Main menu F5 Settings F4 Axis F1 Infeed axis F1 Infeed parameters

Pressing the F2 key

Pressing the F3 key
Function key F5: Increase value.

Pressing the F5 key
increases the value of the highlighted selection.
Function key F6: Decrease value.

Pressing the F6 key
decreases the value of the highlighted selection.
Reference Measure
At every start-up, the machine must be referenced. The infeed axis moves to a reference
position and enters this value into memory as its present position.
Fast/slow point
This dimension determines how far from the target position the speed of the feed unit will
be reduced to slow speed. Before each positioning, the fast/slow point is calculated by the
control unit. If the calculated value is shorter or longer than the minimum or maximum
fast/slow point, then the min. or max. values are used for the positioning.
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Gradient
The gradient is used to determine the fast/slow point. (Factory preset at 1.50)
Pre- stop point.
This dimension determines the far before reaching the target position the infeed unit will be
switched off, to compensate for inertia.
Tolerance
Adjusts the range used to determine whether to issue a fault message. By entering the
tolerance, the positioning will be checked to ensure its position is within the range set. If a
tolerance of 0,00 mm is programmed, then the tolerance check is switched off.
Pulse - Distance
Adjusts the encoder (number of pulses / inch) .
Counter direction
Pressing the F5 or F6 key changes the counter direction of the measuring system.
Software limit switch (+)
Adjusts the positive end position (away from the saw blade) of the supply axis.
Software limit switch (-)
Adjusts negative end position (toward the saw blade) of the supply axis.
Timer
Slow down
Adjusts the timer for the brake when working in manual operation to allow the unit to slow
down prior to engaging the brake.
Position reached
Adjust the time delay after reaching the target position that a signal will be sent to the
controller that the position has been reached.
Stand still
Adjust the time delay after all movement of the axis that a signal will be sent to the
controller that all movement has ceased.
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5.7.4.1.2 Automatic Data (page 47).

Main menu F5 Settings F4 Axis F1 Infeed axis F2 Automatic Data

Pressing the F2 key

Pressing the F3 key
Function key F4: Sign.

Pressing the F4 key
changes the sign of the current highlighted variable.
Start position
If the machine is started in the automatic without material mode, the feeding gripper will
move to this position.
Zero measure
Is the distance between saw blade and the back surface of the material clamp. This
dimension is used for the automatic trim cut in that the material is positioned against the
closed material clamp. The machine will then move the material to the proper position to
make the trim cut.
Slack compensation
During the backward movement of the feeding gripper (invert) in the automatic operation a
cutting length difference occurs by the opening and closing of the supply gripper. This
machine constant will compensate for this movement. For every backward stroke the value
will be added to the cutting length. If a negative value is entered then the value will be
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subtracted from the cutting length. If a value of 0.00 mm is entered, then the compensation
is not active.
Loop distance
Here it is to enter the loop distance for the positioning.
Max. positioning length
Here it is to enter the maximum positioning length.
SWE (-) Manual
Here it is to enter the position of the software limit switch for manual operation.
NS backward for residual
Here it is to enter in relation to the position of the light barrier material-end the size which
the supply gripper moves backward if material end is recognised.
NS backward if residual to long
Here it is to enter in relation of the position from the material end-light barrier the length
of the way that the supply gripper moves backward if it is detect material end. Therefore it
is possible to fix the residual slightly longer. Selection on page 13.
Collecting length
Here it is to enter the pick up length (Optional)
Min. trim cut
Adjusts the minimum trim cut length.
Min. cutting
Adjusts the minimum cutting length.
Max. cutting
Here it is to enter the max. cutting length.
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5.7.5 Motor Controller (page 52).

Main menu F5 Settings F5 Motor controller
In this menu it is possible to read about the several motor controller types and read
respectively modify the corresponding controller parameter.
Only for stuff!
5.7.5.1 Motor controller parameterise
Entering the password (Password level 3) F3 Entering password.
Selection Controller type with F5 respectively F6.

Function writing with F5 respectively F6.
Entering the number.(for parameter set 2 code digits from 2001 upwards).
Entering Subcode number Return (only necessary if a subcode exists
Input data (observe 4 digits after decimal point).
With key F2
save.
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5.7.5.2 Motor controller read-out
Entering password (Password level 3) F3 Entering password.
Selection Controller type with F5 respectively F6.

Function read with F5 respectively F6.
Entering code number.
With key F2
save.
The value of the controller are displayed in the answer window as answering value.
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6 Automatic operation
6.1 Reference movement
In order for the PLC to recognise the position of the length location stop, every time the
main power is turned on, the machine must perform a reference cycle (LED will be
flashing). Therefore, the hydraulic pump is switched on and by pressing the Automatic
key one time, the automatic reference cycle is started. During the reference cycle, feed
gripper is opened briefly and moved forward to the limit switch "dimension + off". When the
limit switch is reached, the direction of the length stop is reversed. When the control unit
receives the Marker pulse from the encoder, the value set as the reference measure in
the machine constants is accepted and plugged into the controller. Once the reference
cycle is complete, the position of the length stop can be monitored in the Diagnose menu.
The reference cycle can every time stopped by pressing the Hydraulic key.
6.1.1 Common conditions!

Basic conditions for any positioning in the manual or automatic mode is that the reference
point has to moved on. The position of the length location stop is to change in the
diagnose menu. An automatically positioning is to do in the automatic operation or in the
menu supply axis, (page 43-> test positioning)
The drive distance of the length location stop is limited by the limit switch dimension + off
and the limit switch supply carriage rear / dimension off.
6.2 Automatic start

Important!
The automatic operation will only start if the operation switch is in the
Automatic position.
6.2.1 Basic condition

It has to program one set totally and stored in the job list.
The automatic is only to start if the work piece is clamped with the gripping jaws or no
material is between the jaws. This distinction is called "Start with Material" or "Start
without Material".
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6.2.2 Start without Material

6.2.2.1 Manual material infeed
After pressing the key Automatic and two hand the gantry vise (optional equipment) and
the supply gripper opens totally and moves forward to the saw blade. The length location
stop will positioned. The material collet will closed and the saw frame is lifted up totally
above. The vertical vise (optional equipment) will opened totally. The supply gripper moves
backward against the length location stop.
Now the automatic LED flashes for indication and the message material insert occurs.
During that position the supply gripper and the supply roller table are released.
After the material rod is transported forward to the closed material collet, then the supply
gripper and the gantry vise (optional equipment) are to fix.
Then the keys "Reset" and 2 hand are to press that the automatic process is still running.
At first the material collet has to open totally. Afterwards the material is positioned. With a
pre-selection without trim cut a good piece will be sawed. For pre-selection with trim cut
at first a trim cut and then a good piece will be sawed.
6.2.2.2 Automatic material infeed (optional equipment)

After pressing the key Automatic and two hand the gantry vise (optional equipment) and
the supply gripper opens totally and moves forward to the saw blade. The length location
stop will positioned. Afterwards the hydraulic zero location stop is raising. The vertical vise
(optional equipment) will be closed and the saw frame is lifted up totally above. The supply
gripper moves backward against the length location stop. The automatical material infeed
starts. After the material rod is transported forward to the zero location stop, then the
supply gripper clamps and the material is positioned. With a pre-selection without trim cut
a good piece will be sawed. For pre-selection with trim cut at first a trim cut and then a
good piece will be sawed.
Note: only for a few machine type the closed material collet works as a zero location stop.
6.2.3 Start with Material

During the start there are two distinctions
1. The saw drive is switched on, the saw works for example at a crop cut.
After pressing the keys Automatic and 2 hand the control unit recognise that the
material is clamped and the saw drive runs. Afterwards the machine waits until the cut
is finished. As soon as the saw drive is switched off and the saw frame is lifted over the
material top edge, then the material outfeed for the first cut takes place.
2. The saw drive is switched off and the saw frame is lifted over the material top edge.
This could be happened, if the material is clamped from a previous machining at the
same cutting line.
After pressing the keys Automatic and 2 hand the control unit recognise that the
material is clamped and the saw drive runs. Afterwards the out feed for the first cut
takes place.
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6.2.4 Inquiry cutting data (optional equipment)

This menu appears if the automatic procedure is started and in the machine the equipment
AFC is installed.
After starting the automatic procedure the following inquiry appears if with the manually
cutting data are to saw continuously or it is to saw with the job data. Depending on the
selection the parameter for blade velocity and feed are imported.
6.3 Automatic stop

6.3.1 Quantity reached
If the automatic operation is interrupt, then the present sawed quantity (actual quantity) is
saved in the set. This set can be later machined off. If during the automatic process the
actual quantity is equal to the nominal quantity, then the set is changed. If there is in the
following set programmed zero for the nominal quantity, then the automatic operation is
switched off.
6.3.2 Material end

6.3.2.1 Machine without depot
If the control unit register that during the backward movement of the supply gripper the
limiting switch respectively light barrier "Material end" has released, then the automatic is
switched off.
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6.3.2.2 Machine with depot (optional equipment)

If the control unit register that during the backward movement of the supply carriage the
limiting switch "Material end" has released, the remaining piece will be refused. Then the
cutting will taken over to the infeed roller train respectively the depot will be stroking one
time forward and an automatical material infeed will taking place.
If during the automatical material infeed no material will arrive at the supply carriage,
because the depot is empty, then the automatic is switched off.
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7 Sawing cycle (optional equipment)

If the machine is equipped with a sawing cycle then it is started by pressing the keys
cycle and 2 hand. At first the material is clamped and the saw drive is switched on. If
the material is sawed the cutting is loosen and the saw frame is lifted up. Afterwards the
cutting is loosely inside the machine ready to take out. The sawing cycle is finished.
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8 Fault messages
Fault messages are always deleted with the "RESET" key.
F1
Emergency cutoff at the magazine is actuate:

The emergency stop on the magazine is not released.
F2
Motor protective switch saw drive has released:

The motor overload switch, the thermo-coupling in the motor, or the frequency
converter for the saw drive has tripped. If the thermo-coupling of the motor has
tripped, the motor must be cooled down. If the fault is from the frequency
converter, the fault can be read on the converter display.
F3
Motor protective switch coolant pump has released:

The motor overload switch Q2 for the coolant pump has tripped.
F4
Motor protective switch hydraulic pump has released:

The motor overload switch Q3 for the hydraulic pump has tripped.
F5
Motor protective switch chip conveyor has released:

The motor overload switch Q4 for the chip conveyor has tripped.
F6
Motor protective switch feeding gripper has released:

converter for the feeding gripper has tripped. If the thermo-coupling of the motor
has released, the motor must be cooled down. If the fault is from the frequency
converter, the fault can be read on the converter display.
F7
Motor protective switch magazine has released:

The motor overload switch Q8 for the magazine drive has tripped.
F8
Motor protective switch supply table roller has released:

converter for the supply table roller has tripped. If the thermo-coupling of the
motor has released, the motor must be cooled down. If the fault is from the
frequency converter, the fault can be read on the converter display.
F9
Blade break down:

The saw blade is broken or too long.
F10
Protection hood are open:

One of the protection doors or a guard is not closed.
F11
Saw blade blocked:

The speed control of the saw drive has tripped. The sensor behind the driven
wheel is dirty or the saw blade is jammed.
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F12
Interruption cutting control

The second limit value of the cutting control has been reached The saw blade
is dull or the feed rate is set too high.
F13
To less coolant in the machine

The coolant level is low. Add coolant
F14
Interruption upward-switch
The saw blade up limit switch is jammed. Clean and lubricate the switch.
F15
To less hydraulic oil in the machine

The hydraulic oil level is low. Add hydraulic oil and check the machine of leaks.
F16
Magazine does not align with the machine

The magazine is not aligned with the machine. Move the magazine forward until
it stops automatically.
F17
Saw frame is not above the material:

The saw frame must be above the material to move the feeding gripper forward.
F18
Automatic start with a shelf change set:

To work with the automatic start, a set must be programmed in the first
compartment of the magazine.
F19
Disturbance light barrier machine

The light barrier on the feeding gripper or the light barrier in front of the zero
stop is blocked or misaligned. Clean and check the alignment
F20
Fault material inlet:

During the automatical loading in the machine the material was jammed or the
bar needs more time then in the menu infeed parameter page 54 programmed
to move through the machine.
F21
Fault pressure switch supply gripper:

The pressure switch on the feeding gripper is not registering the vise is
clamped. Clean and check the calibration
Fault pressure switch material vise
The pressure switch on the material vise is not registering the vise is clamped
Clean and check the calibration
F22
F23
Fault pressure switch sawing piece gripper

The pressure switch on the outfeed gripper is not registering the gripper is
clamped. Clean and check the calibration
F24
Material vise is not open:

The limit switch material vise open is not registering the material vise is fully
open. Clean and check the calibration
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F25
Disturbance light guard magazine:

If the light barrier at the infeed roller train senses material, it is not possible to
move the magazine. The material must be moved out of the light barrier or the
photo cell must be cleaned and/or adjusted.
F26
Supply gripper is not open:

Limit switch Feeding gripper open is not registering the feeding gripper as
open. Clean and check the calibration.
F27
Sawing piece gripper not open:

Limit switch outfeed gripper is not registering the gripper is open. Clean and
check the calibration
F28
Feeding gripper position missed:

The positioning of the feeding gripper is not within the tolerance field or one of
the over-travel end switches was touched during the positioning. The position
accuracy can be adjusted in the machine constants.
F29
Assort carriage position not reached

The positioning of the sorting gripper is not within the tolerance field or one of
the over-travel end switches was touched during the positioning. The position
F30
Material final position reached

The sawed piece is too long for dumping or the limit switch at the end of the tilt
table is jammed.
F31
Fault material back shipment:

The material was not detected during its removal from the machine.
F32
Wrong material width:

The material width being loaded into the machine does not match the
programmed material width.
F33
Disturbance feeding gripper axis:

The positioning control unit of the feeding gripper has faulted.
No respectively wrong signals are recognised from the shaft encoder as soon
as the supply gripper is moved. Shaft encoder proofing respectively exchange.
Please call the service department for assistance.
F34
Interruption sorting gripper axis

The positioning control unit of the feeding gripper has faulted.
No respectively wrong signals are recognised from the shaft encoder as soon
as the supply gripper is moved. Shaft encoder proofing respectively exchange.
Please call the service department for assistance.
F35
Disturbance control voltage:

The control fuse F2 is defective. Check the wiring and replace the fuse.
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F36
Fault tipping table lift up

The tipping table is jammed and can not move to the top end position or one of
the limit switches for the table up is out of adjustment or defective.
F37
Fault tipping table lower

The tipping table is jammed and can not move to the lower end position or one of
the limit switches for the table down is out of adjustment or defective. The brake
on the table up/down system may be jammed or defective
F38
Fault sawing piece gripper out feed

The sorting gripper is jammed and did not move to the correct position.
F39
Disturbance lift roller (axial out feed)

The motor overload switch for the lift roller has tripped.
F40
Interruption spray cooling

The oil level of the spray cooling unit is low or the air pressure is too low.
F41
Input in the magazine depot 2 is not finished:

The job programmed in the second compartment of the magazine is
incomplete.
F42
Wrong set data

To saw automatical the following job parameter are to program. Valid cutting
length, nominal quantity, higher actual quantity, valid cutting length, amount of
bars minimal 1, amount of layers minimal 1.
F43
Fault data take over marker system

To mark a section it is first to copy a text from the PC to the marker system. If the
marker system gives not an answer after a firm programmed control time then
such a fault is happened. Either the marked text is to long or the marker system
is switched off.
F44
Limit switch above

The limit switch of the saw frame up is defective or out of adjustment.
F45
Limit switch down

The limit switch of the saw frame down is defective or out of adjustment.
F46
Wrong operation mode

The operation mode switch must be in the automatic position to operate the
machine in automatic. The operation mode switch must be in the manual position
to operate the machine manually. .
F47
Material end
During automatic operation the sensor on the feeding gripper does not detect
any material.
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F49
Container prohibition!
If a container is programmed in a set and at least one piece of the set is in the
container then the container is not available for another set. To use the
container, it is necessary to clear the set already deposited into the container.
F50
Angle position not reached

The positioning of the mitre table is not in the tolerance field or one of the overtravel limit switches was touched during the positioning. The positioning accuracy
can be adjusted in the machine constants.
F51
Wrong angle during Auto-Start with material

If material is in the machine and the automatic cycle started, the saw frame must
first be pre-positioned to the programmed angle.
F52
Interruption axis angle adjustment

The positioning control unit of the mitre unit has faulted. Please contact your
service department for assistance.
F53
Fault pressure switch vertical vise

The pressure switch for the vertical vise is out of adjustment or defective.
F54
Vertical clamp not totally open

The vertical clamp has jammed or the limit switch Vertical clamp open is
defective.
F55
Fault sensor voltage cutting control:

The sensor voltage of the cutting control sensor too low or too high. Normal
voltage with the guides clamped is approximately 5V (+/- 1V). The sensor
voltage may be read in the analyse menu. If the voltage drops under 1V or
increases above 9V this fault message will appear.
F56
Start without Material

To start the automatic, material has to be in the feeding gripper and the machine
if the machine runs.
F57
Blade location monitor

The saw blade has pulled out of the guides during the saw frame lifting or the
blade location sensor is out o adjustment or defective.
F58
Residual stock is full

The stillage area of the magazine is full or the limit switch residual stock is full
is defective.
F59
Depot table is full

Material is occupying the depot table.
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F60
Motor protective switch sorting gripper has released

The motor overload switch or the thermo-coupling in the motor or the frequency
converter for the sorting gripper has tripped. If the thermo contact from the motor
has tripped, the motor must be cooled down. If the fault is from the frequency
converter, the error can be read on the converter display.
F61
Sorting gripper not in the start position

After disposal, the sorting gripper must be moved to its starting position before
starting the automatic operation id the saw drive is on.
F62
Sorting gripper locked up

To push away in the direction of the clamping side the sawing piece gripper has
not to be in the clamping area.
F63
Saw blade is not stretched

The blade tension valve is not in the correct position or the pressure switch is out
of adjustment or defective.
F64
Sorting gripper open

If the sorting gripper is at the saw blade and the saw frame is lowered, the
sorting gripper must first be closed to prevent a collision of the guide arm with the
sorting gripper.
F65
Measuring unit position not attained:

The positioning of the measuring unit is not within the tolerance set or one of
the over-travel limit switches was touched during the positioning. The
positioning accuracy can be adjusted in the machine constants.
F66
Fault material out feed

The light barrier of the transfer conveyor has not detected material within the
programmed time set in the machine constants .
F67
Automatic process interrupt

The automatic cycle has been interrupted longer than the programmed allowable
time set in the machine constants.
F68
Reference point lost

The axis have lost their positions. The reference cycle must be repeated.
F69
Motor protective switch measure car has released

The motor overload switch for the measuring car has tripped.
F70
Transfer conveyor not in start position

The transfer conveyor has not returned to its start position.
F71
Fault solenoid measuring system

Fault in the distance measuring system the feeding gripper. Check solenoid
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band respectively sensor.

F72
Motor protective switch out feed roller table has released.

The motor overload switch or the thermo-coupling contact in the motor or the
frequency converter for the out feed roller table has tripped. If the thermocoupling from the motor has released, the motor must be cooled down. If the
fault is from the frequency converter, the error may be read on the converter
display.
F73
Motor protective switch gear adjustment has released

The motor overload switch for the gear adjustment has tripped.
F74
Motor protective switch transverse conveyor has released

The motor overload switch for the transverse conveyor on the infeed side has
tripped.
F75
Feeding gripper not in the start position

The feeding gripper is not in its starting position.
F76
Out feed roller table is taken

Material is detected on the out feed roller table.
F77
Fault out feed roller table

The material is jammed on the roller table.
F78
Material storage full

The material storage area is full or the limit switch is defective.
F79
Outfeed roller table in the wrong postion

The drawbridge is in the wrong position or one of the limit switches, roller table
up or down, is defective. .
F80
Heavy Residual work piece

The weight of the material is over the limit of the magazine. The material must
be moved in to the machine manually.
F81
Emergency stop switch, magazine residual storage actuate

The Emergency stop on the stillage storage is activated.
F82
Emergency stop switch depot in front actuate

The Emergency stop on the depot in front is activated.
F83
Emergency stop depot behind actuate

The Emergency stop on the depot behind is activated.
F84
Emergency stop machine actuate

The Emergency stop on the machine is activated.
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F85
Disturbance safety zone assort devise

A protective door is opened or a light barrier has been broken.
F86
Ejector not in start position

The ejector has not returned to its start position.
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F87
Vertical vise out feed side not open totally

The vertical vise is jammed or the limit switch is out of adjustment or defective.
F88
Bunch clamping devise not open totally

The limit switch bunch clamping vise open is defect or the vertical vise is
jammed.
F89
Wrong rod quantity

The programmed rod quantity is incorrect compared to the actual rod quantity or
one of the limit switches which records the rods are defect.
F90
Motor protective switch feeding gripper has released

The motor overload switch, the thermo-coupling the motor, or the frequency
converter for the feeding gripper has tripped. If the thermo-coupling from the
motor has tripped, the motor has to be cooled down. If the fault is from the
frequency converter, the type of error can be read on the converter display.
F91
Emergency cutoff feeding gripper actuate

The Emergency stop on the feeding gripper is to activated.
F92
Disturbance axle feeding gripper

The positioning control unit of the feeding gripper has faulted. Please contact
your service department.
F93
Fault push button switch feeding gripper

The push button switch for the feeding gripper is misadjusted or defective.
F94
Gripper feeding gripper not open totally

The limit switch, feeding gripper open, is defective or the feeding gripper clamp is
jammed.
F95
Feeding gripper position not attained

The position of the feeding gripper is not within the tolerance field or one of the
over-travel limit switches was pushed during the positioning. The position
F96
CAN-Bus Timeout (FU)

The CAN-bus connection to the frequency converter is interfered. Check wire
ring, plug and bus-modules.
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F97
Measure location stop not down

In the lockup area of the machine, the measure location stop must be down to
move the measuring unit.
F98
Measure car locked up

The measuring unit is in the lockup area of the machine. The measuring unit can
only be moved backward.
F99
Emergency cutoff actuate

The Emergency stop on the control panel is activated.
F100 Emergency cutoff panel B

The Emergency stop on panel B is activated.
F101 Emergency cutoff panel D
The Emergency stop on panel D is activated.
F102 Emergency cutoff panel E
The Emergency stop on panel E is activated.
F103 Emergency cutoff protection guard
The Emergency stop on the protection guard is activated.
F104 Emergency cutoff panel
The Emergency stop on the panel is activated.
F105 Cross transport position not attained
The positioning of the cross transport is not within the tolerance field or one of
the over-travel limit switches was pushed during the positioning. The position
F106 Disturbance axle cross transport
The position control unit of the cross transport has faulted. Please contact your
service department.
F107 Sorting gripper in wrong position
If the automatic is started with sorting gripper, the sorting gripper must be in the
down position. If the automatic is started without sorting gripper, the sorting
gripper must be moved to the farthest position and raised.
F108 Interruption protection machine
The light guard of the machine was interrupted.
F109
Disturbance axis sorting devise

The positioning control unit of the sorting devise has faulted. Please contact
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F110 Collision hazard

The roller tables of machines with drawbridge roller tables must to be in the down
position before the machine can turn. For machines with shunt rollers the shunt
rollers has to be in the correct position before the machine can turn.
F111 Motor overload switch of the longitudinal nut has tripped
The motor overload switch of the longitudinal nut has tripped.
F112 Wrong terminal active
For sawing short lengths, the main terminal has to be selected,
F113 Sorting gripper position not attained
The position of the sorting gripper is not within the tolerance field or one of the
over-travel limit switches was pushed during the positioning. The position
F114 Cut off key infeed side
The Emergency stop on the infeed side is activated.
F115 Cut off outfeed side
The cut off key from the outfeed side is to unlock before an operating procedure
is possible.
F116 Interruption axis measure car
The positioning control unit of the measuring unit car has faulted. Please contact
F117 Interruption marker system
The marker system has interrupted. Please call the service department for
assistance.
F118 Measure location stop not clamped
After the clamping of the measure location stop the switch Clamping loosen is
to switch off that it is possible to actuate other functions.
F119 Interruption central lubrication
The central lubrication system pressure is too low. Check the level of coolant in
the system and inspect the system for leaks.
F120 Interruption solenoid
The motor overload switch for the solenoid has released.
F121 Motor protective switch gantry drive has released
converter for the gantry drive has tripped. If the thermo-coupling in the motor has
tripped, the motor must cool down before the fault can be cleared, If the fault is
from the frequency converter, the type of error can be read on the converter
display.
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F122 Interruption axle gantry

The positioning group of the gantry has faulted. Please contact your service
department.
F123 Gantry position not attained
The position of the gantry is not within the tolerance or one of the limit switches
was pushed during the positioning. The position accuracy can be adjusted in the
machine constants.
F124 Limit switch gantry vise above
The limit switch gantry vise above does not operate. It is defect or wrong adjust.
F125 Limit switch gantry gripper below
The limit switch gantry gripper below does not operate. It is defect or wrong
adjust.
F126 Fault limiting switch container full
The limit switch Container full is misadjusted or defective.
F127 Auto-Start with solenoid on
During the automatic start the solenoid must not be switched on.
F128 Take off table used
During the automatic start there must not be any material on the take off table for
the gantry. Remove the material or check the limit switch Take off table used.
F129 Fault gantry outfeed
The gantry is jammed and can not move to the correct position.
F130 Fault limiting switch take off table used
The limit switch take off table used is misadjusted or defective.
F131 Bus fault
There is a fault on the bus system. Check the connections on the bus system
and or call your service department.
F132 Fault limiting switch solenoid on/off
The limit switch Solenoid on/off is misadjusted or defective..
F133 Material size too large, wrong container selected
The material diameter is too large for the programmed container. Please select a
container on the other side.
F134 Attention ! Solenoid switch on period exceed
The programmed time in the machine constants for the solenoid to be on has
been exceeded. The solenoid is switched off to protect it from overheating or
destruction.
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F135 PLC-Battery empty

If this fault message appears, DO NOT TURN OFF THE MAIN POWER TO THE
MACHINE. The battery which maintains the PLC program is low. Loss of power
will cause the PLC to lose its program. Replace the battery in the PLC.
F136 Chip accumulation under the saw blade guide
There is an obstruction under the fixed blade guide preventing the saw frame
from lowering. Clean away the obstruction
F137 Cut off desk A
The cut off key at the operation panel A is to unlock that it is possible to work
with the sawing machine.
F138 Cut off desk C
The cut off key at the operation panel C is to unlock that it is possible to work
with the sawing machine.
F139 Cut off desk F
The cut off key at the operation panel F is to unlock that it is possible to work with
the sawing machine.
F140 Protection area machine clamping side interrupt
The protection area respectively the light grille of the machine from the clamping
side are interrupted.
F141 Protection area machine location stop side interrupted
The protection area respectively the light grille of the machine from the location
stop side are interrupted.
F142 Protection area outfeed side clamping side interrupt
The protection area respectively the light grille of the machine from the outfeed
F143 Protection area outfeed side waste bin interrupt
The protection area respectively the light grille of the machine from the outfeed
F144 Protection area infeed side interrupt
The protection area respectively the light grille of the machine from the infeed
F145 Motor protection coolant return pump released
The motor protection switch from the coolant return pump has released.
F146 Motor protection HY-pump Transport devise released
The motor protection switch from the hydraulic-pump for the transport devise has
released.
F147 Interruption hydraulic-heating machine
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The motor protection switch from the hydraulic heating for the sawing machine
has released.
F148 Interruption hydraulic-heating transport devise
The motor protection switch from the hydraulic heating for the transport devise
has released.
F149 Motor protection chip conveyor II released
The motor protection switch from the 2. Chip conveyor has released.
F150 Motor protection scrap conveyor released
The motor protection switch from the scrap conveyor has released.
F151 Interruption central lubrication machine
No pressure rise at the central lubrication devise at the machine could occur
during the defined control time. It is to inspect if enough lubricant in the container
of the central lubrication devise is or a leakage at the container occur.
F152 Interruption central lubrication supply gripper
No pressure rise at the central lubrication devise at the supply gripper could
occur during the defined control time. It is to inspect if enough lubricant in the
container of the central lubrication devise is or a leakage at the container occur.
F153 Interruption central lubrication cutting gripper
No pressure rise at the central lubrication devise at the cutting gripper could
occur during the defined control time. It is to inspect if enough lubricant in the
container of the central lubrication devise is or a leakage at the container occur.
F154 Motor protection infeed roller train supply released
The motor protection switch of the infeed roller train has released.
F155 Motor protection cross conveyor infeed side released
The motor protection switch of the cross conveyor at the infeed side has
released.
F156 Motor protection link conveyor outfeed roller train released
The motor protection switch of the link conveyor at the outfeed roller train has
released.
F157 Motor protection chain conveyor I released
The motor protection switch from the chain conveyor 1 has released.
F158 Motor protection chain conveyor II released
F159 Motor protection chain conveyor III released
F160 Motor protection switch Q12 released
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The motor protection switch Q12 has released.
F161 Motor protection switch Q13 released
The motor protection switch Q13 has released.
F162 Fuse F1 released
The fuse F1 has released
F164 Fuse F8.1 released
The fuse F8.1 has released
F171 Fuse F25/F27 released
The fuse F25 or F27 has released
F172 Fuse F26/F28 released
The fuse F26 or F 28 has released
F174 Min. level hydraulic oil machine remain
The minimal oil level of the hydraulic oil is remaining. Refill oil.
F175 Min. level hydraulic oil machine remain
The maximum oil level of the hydraulic oil is exceeding. Drain oil.
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F176 Min. level hydraulic oil transport devise remain

The minimal oil level of the hydraulic oil from the transport devise is remaining.
Refill oil.
F177 Max. level hydraulic oil transport devise remain
The maximum oil level of the hydraulic oil from the transport devise is exceeding.
Drain oil.
F178 Barrier stair infeed side open
Close barrier at the stairs.
F179 Barrier infeed roller train open
Close barrier at the infeed roller train.
F180 Material depot I occupied
During the automatic start a less amount of material has to be on top of the
material depot. Remove the material or inspect the limit switch material depot I
occupied.
F181 Material depot II occupied
material depot. Remove the material or inspect the limit switch material depot II
occupied.
F182 Material depot III occupied
material depot. Remove the material or inspect the limit switch material depot III
occupied.
F183 Protection hood open
Close protection hood.
F184 Interruption limit switch axis cutting gripper
Inspect the limit switch from the cutting gripper.
F185 Over heating switch cabinet
The temperature in the switch cabinet are exceeded. Enable cooling.
F186 Interruption zero location stop
The zero location stop for automatic material infeed operates incorrect. Inspect
limit switch respectively pressure switch.
F187 Positioning impossible
A positioning is not possible. Please enter a new position and try once again.
F188 Fault axis card
The axis card sends a fault. Please call the service department for assistance.
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F189 Disturbance limit switch axis supply carriage

Inspect limit switch from supply carriage.
F190 Protection area interrupt
The protection area respectively light grille at the infeed side are interrupt.
F191 Cut off PC
The cut off key at the PC is to unlock for operating with the sawing machine.
F192 Interruption heating
The motor protection switch of the heating system has released.
F193 Interruption compressed air
Inspect compressed air system.
F194 Motor protection Servo saw frame released
The motor protection switch for the servo-drive of the saw frame has released.
F194 Interruption cutting pressure sensor
A fault is occurring at the cutting pressure regulation. Inspect adjustment
respectively stress.
F196 Motor protection material disposal
The motor protection switch for the material disposal has released.
F197 Infeed roller train occupied
During the automatic operation no material has to be on top of the infeed roller
train. Remove the material or inspect the light barrier ZR occupied.
F198 Pressure switch gantry vise
The pressure switch of the gantry vise for clamp is incorrect adjust respectively
defect.
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9 Safety device/guards
Hazard!
Protection hoods are avoiding the access to the internal machine side. It
is installed to guaranty the safety to the stuff and is not allowed to take
away or remove.
9.1 Wheel cover

Both wheel covers are secured by limit switches. If one of the wheel covers is opened then
the machine is switched off. The interruption is shown by the signal bulb "Disturbance" and
by a fault message.
9.2 Motor overloads

The several drive motors are protected by separate motor protective switches. If one of the
motors fails then the machine is switched off automatically. The interruption is shown by
the signal bulb "Disturbance" and on the display appears which motor protective switch
has set off.
9.3 Band slip monitor

The machine is equipped with an electronically speed control. If the saw band slides at the
driving wheel the speed control switch off the drive. The interruption is then indicate by the
indicator lamp "Disturbance" and by a fault message.
9.4 Breakage band control

If the saw band breaks the machine is switched off. The interruption is shown by the signal
bulb "Disturbance" and by a fault message.
9.5 Band deflection monitor (Specific equipment)

In the machine data it is possible to set 2 limiting values. If the divergence exceeds the
second limiting value, then the saw bow lifts up and the saw drive is switched off. The
interruption is indicated by the indicator lamp "Disturbance" and by a fault message.
9.6 Coolant flow monitor (Specific equipment)

The machine is equipped with a flow controlling for the coolant. If the coolant should not
reach the saw band the machine is switched off. The interruption is shown by the signal
bulb "Disturbance" and by a fault message.
9.7 Coolant level monitor (Specific equipment)

The machine is equipped with a level controlling for the coolant. If the coolant sink during
the sawing process to deep then the machine is switched off. The interruption is indicated
by the indicator lamp "Disturbance" and by a fault message.
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9.8 Band location monitor (Specific equipment)

This controlling unit reacts if during the lifting up process the band clamps and slides out
off the guides.
To lift up the saw bow even so, in the menu "extra function", is to program "release saw
bow lift".
The quitting of the disturbance is to do by pressing the key "RESET".
9.9 Protective fence (Specific equipment)

The doors of the protective fence are secured by limit switches. If one of the doors opened
then the machine is switched off. The interruption is shown by the signal bulb
"Disturbance" and by a fault message.
9.10 Light barrier (Specific equipment)

Automatic sawing machines with roller trains or cross conveyors are protected with light
barriers. This kind of protection is necessary for automatic operations with these
machineries.
If the light barrier is interrupt, then the automatic went over into the stand by that means
after acknowledge the message the automatic process is continued. The interruption is
indicated by the indicator lamp "Interruption" and by a fault message.
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10 Maintenance
Hazard!
Maintenance- and maintain work is only to do by a switched off sawing
machine and the saw bow is to lift in the lowest position, safety to
support respectively. The machine is to protect against an unauthorised
switch in!
10.1 Coolant
Check level of coolant daily.
If necessary coolant emulsion needs to be filled up.
Change coolant monthly and clean the tank.
10.2 Grease lubrication

The sawing machine is to lubricate in accordance to the maintenance- and lubricant
diagram.
10.3 Gear box

The saw drive gear has a long-duration oil filling. In case of standard working conditions no
oil change is necessary.
If the machine is working in a 3-shift operation or with unfavourable conditions every
16.000 working hours the oil could be changed. Please ask company Behringer for the
recommended quality and quantity of the oil.
The weakly maintenance is only control of leakage.
10.4 Hydraulic
Attention!
While working at the hydraulic system, the saw bow is to lift in the lowest
position or safety to support and the hydraulic pump is to switch off!
The hydraulic pump is to protect against an unauthorised switch in!
The oil level in the hydraulic aggregates is to control weekly by the oil sight-glass. If
necessary it is to refill hydraulic oil.
Change of the oil is necessary after each 2.000 working hours, minimum 1 change per
year. The quantity of the oil is mentioned in the greasing plan.
The oil is to filter before it is filled in.
Attention!
After working time of four weeks it is possible that a leakiness at the
hydraulic connections exists. Therefore all connections wires and also all
hydraulic connections should be strongly tightened if necessary.
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10.5 Chip brush

Check power driven chip brush app. every ten hours of operation and adjust if necessary.
After approx. 50 hours of operation the chip brush should be replaced. The chip brush is in
the right position if its bristles project to 2/3 of the tooth space depth into the saw band.
10.6 Carbide blade guides

Attention!
While working at the blade guides, the saw frame is safety to support and
the hydraulic pump is to switch off!
The hydraulic pump is to protect against an unauthorised switch in!
The carbide guides must be cleaned after every blade exchange. After strong impurities
especially by using of the spray system you must rebuild the carbide guides to clean it and
check if the carbide plates are ok.
10.7 Wheel cases

The wheel cases have to be cleaned by changing the saw band in order to avoid that chips
accumulate.
10.8 Chip conveyor (Specific 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 pushingin-shaft of the conveyor or in the machine base.
Hazard!
The operator has to ensure that nobody put its hand into the chip eject
area during the process by insert a container with appropriate height to
avoid such situation. If it is used moveable protective devises than they
are to lock up with starting the drive of the chip conveyor.
10.9 Measuring unit (Specific equipment)

Bevor work on measuring unit the measuring stop must be in lower position.
When it's not possible to bring in low position the measuring stop, you must protect it with
an supporting beam.
10.10 Change of battery

The battery from the operation terminal BT41 is to change at least after
two years.
The battery is to change while the operation panel is switched on.
Doing this the main switch must be still switched on.
In a powerless state the data in the RAM are lost during the battery
changing.
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10.10.1 Operation steps

1. Foreseen electrostatic discharge at the hat rail respectively at the connecting earthing.
2. Remove cover for the Lithium-Battery with the help of a screw driver.
3. Take out the battery from the brackets by pulling at the pulling strip. (Dont touch the
battery with a tong or a tweezers short circuit) The battery has be only touched at
the front side. To take the battery out it is allowed to use a insulated tweezers.
4. Insert new battery with the correct polarity. Therefore the eject strip is to lift up and the
battery with the + side is to insert into the direction of the code switch. To take out the
battery it is to observer that the eject strip is under the battery.
5. The oversize end of the pull out strip is to move under the battery, that it will not be
seen.
Battery-Type :
Lithium Battery 3 V / 950 mAh
10.11 Preplacement and Cleaning of Filter Mat

Remove cover to replace filter mat. Wash filter mat in water of up to 40C, with a mild
detergent added if necessary. It is also possible to beat, vacuum or to blow with
compressed air.
In case of greasy substances: Wash filter mat in benzine, trichorethylene or warm water
with grease solvent added.
Do not wring nor use sharp jet.
ATTENTION!
The function of filter-fan is guaranted only by regular cleaning of mat.
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10.12 Lubricants
Hydraulic oil
Gearbox oil:
Greasing oil:
Coolant:
Spray oil
HLP 46 (DIN 51524)

see lubrication plan
CLP 68 (DIN 51502)
BSK 88 from BEHRINGER GmbH with 12 %
mixing in water
BSM94 or BSM 2000 from BEHRINGER
Important!
When disposing used lubricants avoid environmental refusing
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11 Troubleshooting
Problem
Possible causes and remedies
Band does not run correctly on

wheels:
1. Clean wheels of chip and coolant.

2. Saw band is squint or incorrectly welded. Replace.
Band vibrating:
1. Reduce/increase band speed.

2. Feed rate set too low. Increase.
3. On thin-walled sections, which are difficult to clamp,
try different band pitches.
Band slipping on wheels:
1. Check band tension is correct (see "Tech. Data").

2. Drive wheel exhibiting resinous coolant residue.
Clean using scraper.
3. Feed rate set too high. Reduce.
Band running out:
1. For long workpieces, check alignment with

machine.
2. Band blunt. Replace.
3. Uneven set. Ask band supplier to replace.
4. Feed rate set too high. Reduce.
Teeth stripping:
1. Chip brush incorrectly set . Adjust.

2. Chip brush worn. Replace.
3. Cutting pressure too high. Set lower feed rate.
If troubleshooting is not possible, call:

BEHRINGER GmbH
- Service Phone +49 7266 207-0
Fax +49 7266 207-500
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12 Ex-operation
Important!
To avoid environmental refusing, the sawing machine is to refuse from an
qualified registered company.
13 Appendix
For appendix see the following pages
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Feed [mm/min]
13.1 Feed in relation to the current regulator position
Current regulator valve

For used current regulator valves are variations until 5% .
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14 BEHRINGER-Cool Jet Lubricate

Device (Special Equipment)
14.1 Safety
The BEHRINGER-Cool Jet Lubricate Device is an
accessory for BEHRINGER-sawing machines.
This operation instruction is to see as
complementing to the instruction handbook for
BEHRINGER- sawing machines.
Therefore the safety regulations of the operation
instruction for sawing machines are valid.
14.2 Operation
14.2.1 Fundamental function
description
During the sawing process a constant lubricant
film is put on the sawblade by the BEHRINGERCool Jet Lubricate Device.
An adjustable dose pump delivers the lubricant from the supply container to the
nozzle head. At the nozzle exit is generate an air-oil-mixture, by pumping adjustable
compressing air which covers the surface of the sawblade.
14.2.2 Switch on and - off of the spray cooling

At the control system of the sawing machine it could be chosen between spray
cooling and swell cooling. This works by an active spray cooling parallel to the
sawing drive.
14.2.3 Calibration of the spray jet

Working procedures to adjust the spray jet:
calibrate working air pressure
calibrate delivery volume
calibrate spray-air-volume
proof calibration
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Attention!
While adjust the spray jet work without metal cutting (feed off)!
14.2.4 Calibrate working air pressure

By turning the controller the net air pressure is decreased to the
working air pressure. The adjustment is readable at the
manometer .
Company adjustment: 4 bar
14.2.5 Calibrate delivering volume

1. Open the locking device locking device is to press to the
top.
2. By turning the lubricant controller clockwise the
delivering volume is increased.
3. Protecting the adjustment by the locking device
locking device pressed downwards.
Company adjustment: 0,75
14.2.6 Calibrate spray air volume

1. Open the lock nut .
2. By turning the spray air levelling anticlockwise the air current increased at the
nozzle tip.
3. Protecting the adjustment by tighten the lock nut
The volume should be small as possible, to prevent an unnecessary atomising.
However it has to be so large, that no oil drop generation at the spray head take
place.
14.2.7 Proof calibration

The adjustment is fine, if the cutting process is finished and an oil film is at the
surface of the sawblade. However there should be no oil drop formation.
14.3 Refilling lubricant

The lubricant reservoir tank has a volume of 1 litre. The refilling of the spray fluid can
done without switch off the sawing machine.
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Important!
It is to avoid a total emptiness of the lubricant reservoir tank during the
working process. If the lubricant container is totally empty it can come to
air bubbles in the lubricant hose or in the micropump. Afterwards the
dose device is to bleed.
For this case see chapter sprayoil-lead/ micropump bleeding.
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14.4 Determine the spray stuff consumption

The spray stuff consumption can determine by the following diagram. The diagram is
based of a working air pressure of 4 bar.
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14.5 Choice of a spray stuff

BEHRINGER BSM 94 is recommend as a lubricant. If it is used an other spray, it should
have the following characteristics.
it is not to use any kind of mineral oil,
it is to spray by a slightly fog,
it has not to attacked the following plastics: Peruban, PA, PU, PE and PC,
it must have a viscosity from 60 40 mm/s by 40C.
Attention!
An unsuitable spray stuff can be injurious to health and can destroy or
minimise the functionality from parts of the dose device, the band guides
and cutting pressure regulation!
14.6 Commissioning
The net air is to connect at the filter regulator.
Filling lubricant reservoir tank.
If necessary spray cooling device is to bleed.
14.6.1 Net air connection

For the cool jet lubricate device is the following net air connection necessary:
Compressed air clutch: DN 7.2
Air pressure: min 6 - max 16 bar
Delivery power of min. 120 l/min (consumption in practice of the cool jet lubricate
device: 40 20 l/min)
14.7 Maintenance / maintains

14.7.1 Automatic condensate emptying
If the controller is continuously under pressure, it is to do a manual bleeding.
If the net pressure (e.g. after the working process is finished) is switched off, the
condensate reservoir tank is bleeded automatically.
14.7.2 Manual condensate emptying

The condensate which is under working pressure is drained by turning the
condensate delivery screw
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14.7.3 Sintered stainless steel filter cleaning

Before cleaning the filter the device has to be pressureless. Do the following
procedures:
1. Filter plates loosen by turning left hand side.
2. Disassembly of the separate cop and filter elements.
3. Sintered stainless steel filter cleaning
Assembling in inverse sequence.
14.7.4 Oil container strainer cleaning

Before cleaning the oil container strainer the device has to be pressureless. Do the
following procedures:
1. Open the container cover.
2. Emptying the lubricant reservoir tank.
3. Remove the nut.
4. Remove filter socket and container pipe from the top side cover.
5. Withdraw the strainer from the pipe.
6. Cleaning the strainer with compressed air (observe the safety regulations!)
Assembling in inverse sequence.
14.7.5 Sprayoil-lead/micropump bleeding

If there are exists air bubbles in the sprayoil-lead or in the micropump the device is to
bleed, because the function is not guaranteed.
1. Note the control value of the lubricant calibration.
2. To operate solenoid valve.
3. To open the lubricant calibration by turning the controller (clockwise) totally.
4. The solenoid valve has to be opened until no air bubbles in the lead or micropump
can be noticed.
5. The noticed control value of the lubricant calibration is to adjust again.
6. Solenoid valve operation finished.
14.8 Disturbance
If there is a disturbance at the cool jet lubricate device please contact:
BEHRINGER GmbH
customer service
phone +49 7266 207-0
fax +49 7266 207-500
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15 Central Lubrication System (Special

Equipment)
15.1 Structure and Function
The grease pump deliver the lubricant from the container into the main pipe to the
distribution sockets with the screwed in dosing valves. After a pressure rise the
dosing valves are deliver a certain determined amount of grease into the connected
lubricating points. A pressure switch in the longest infeed pipe controls the correct
pressure rise. Afterwards the pump is switching off. During the rest period of the
pump the pressure will degrease by an internal pressure relief valve. The dosing
valves are moving backward to the start position. The lubrication cycle is finished.
15.2 Lubricant scope

By the central lubrication devise are feeded usually all lubricant points. The total
amount and all the bearings are shown in the corresponding greasing diagram. The
lubricant points which are not feeded by the central lubrication devise are marked
particularly in the diagram.
The lubricant volume is adapt to the size of the dosing valve in combination with the
cycle time of the pump related to the consume of the corresponding lubricant point
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15.3 Commissioning
The central lubricant system will be delivered ready for work operating. Further
commissioning measurements are not necessary.
15.4 Operation
15.4.1 General
The indication and controlling of the central lubrication system will be done by the
machine control unit. (Standard settings: grease interval = 120 minutes; pump
running time max. 60 seconds).
All settings are done internally before shipment. Changes of the setting data are
usually not necessary and have to be not taken place without consultation of
company Behringer.
15.4.2 Refill Lubricant

Before the lubricant is filled in it has to be stirred powerful, to guarantee a
homogenise consistency of the grease.
For refilling the lubricant container the cover is to remove and the lubricant is to fill in
until the upper limiting sign.
Attention! It is only to use special lubricant of company Behringer,

therefore see chapter 5.
15.5 Lubricant selection

It is only to use special lubricant of company Behringer.
Other lubricants have to be proofed by co. Behringer and accepted.
The consume of not accepted lubricant type are impair the central lubrication system
or collapse them.
15.6 Maintenance
The central lubrication system is maintenance-free .
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HBP530A-CNC
15.7 Lubricant points and pipe ways
15.8 Troubleshooting
If troubleshooting are on the central lubrication system , call:
BEHRINGER GmbH
- Service Phone +49 7266 207-0
Fax +49 7266 207-500
Rev 07.02.11
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Status 46/04
HBP530A-CNC
BA85308
Status 46/04
EC-Conformity Declaration
Producer
Behringer GmbH, Machine works and cast iron

Industriestrae 23, 74912 Kirchardt
Declares with this the following product:

Product name :
Band saw Type name :
Serial number:
Year of construction
All relevant provisions of:
Machinery directive (MD) 2006/42/EC
corresponds.
The machinery is as well conform with the standards of:
Low voltage directive 2006/95/EC1), as well as
Electromagnetic compatibility directive 2004/108/EC2).
The following harmonized standards are applied:

EN 13898
DIN EN 12100-1
DIN EN 12100-2
DIN EN 60204-1
Machine tools Safety Sawing machines for cold metal

Safety of machinery- Basic concepts, general principles for designPart 1: Basic terminology, methodology
Safety of machinery- Basic concepts, general principles for designPart 2: Technical principle- Amendment
Safety of machinery- Electrical equipment of machines Part 1: General
requirements
Responsible for documentation:
Behringer GmbH, Machine works and

cast iron, Industriestrae 23
74912 Kirchardt
Kirchardt,
Date, signature
Christian Behringer (company management)
Signatory/details to signatory
1)
signature
The safety objectives of the voltage directive 2006/95/EC are according appendix I Nr. 1.5.1 MD 2006/42/EC abide. .
2)
Electromagnetic compatibility directive 2004/108/EC in recital (19): in acount to the specific characteristics stationary plants are the EC
conformity declaration and a CE certification not necessary
Rev 07.02.11
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Behringer 530a

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Behringer 530a

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Operating Instructions

Instruction for use

Rust protection paint

4.1 Description control panel

5.1 Terminal description

6.1 Reference movement

Sawing cycle (optional equipment)

Feed in relation to the current regulator position

BEHRINGER-Cool Jet Lubricate Device (Special Equipment)

Central Lubrication System (Special Equipment)

1.2 Explanation of Symbols

1.3 Qualified Personnel

1.4 Proper Operation

Deviations from normal operation (e.g. increases in power consumption, temperature or

1.5 The Workplace

1.6 Location of the Operating Instructions

1.7 Emergency Stop

1.8 Common safety regulations

2.3 Electrical connections

3 Instruction for use

3.3 Saw band choice

4.1 Description control panel

Two hand operation

4.2 Switch on and off

4.3 Saw frame

4.4 Clamping device

4.4.2 Supply gripper

4.4.3 Clamping pressure

4.4.4 Bunch clamping device (Optional equipment)

4.4.5 Vertical vice (Optional equipment)

4.4.6 Gantry vise (Optional equipment)

4.5 Saw drive

4.6 Cutting velocity

4.7 Feed and Cutting pressure adjustment

4.8.2 Spray cooling unit (optional equipment)

4.8.3 Temperature range

4.9 Sawband change

4.10 Supply Carriage

4.11 Length location stop nut (LAM)

4.12 Chip conveyor (Optional equipment)

4.13 Roller train

4.14 Point light

4.15 Laser (optional equipment)

4.16 Material shaking conveyor (specific equipment)

4.17 Cutting control unit (optional equipment)

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

4.18.1 Cutting parameter

4.18.3 Material width

4.19 Cope devise (optional equipment)

5.1.1 Menu structure

Main menu (1)

F1-Infeed parameter (54)

F5-Motor controler (52)

5.1.4 Display - Symbolic

5.1.5 Function key:

Vertical Clamp open

Vertical vise clamping

Portal Clamp open

Portal Clamp clamping

5.2 Main menu (page 1)

5.3 Automatic Menu (page 2)

5.3.1 Latest state of data (page 66)

Description of the single chapters: