User Manual for Rotabroach models including: ELEMENT 50-1A AUTO Magnetic Drilling and Tapping Machine, ELEMENT 50-1A, AUTO Magnetic Drilling and Tapping Machine, Drilling and Tapping Machine, Tapping Machine
Rotabroach
Technical - Rotabroach
File Info : application/pdf, 30 Pages, 2.39MB
DocumentDocumentElement 50 AUTO Manual Original Instructions June 2022 Magnetic drilling & tapping machine Model Number ELEMENT50/1AUTO , ELEMENT50/3AUTO This machine is CE approved. OSL Cutting Technologies Burgess Road Sheffield, South Yorkshire United Kingdom S9 3WD Tel: +44 (0) 114 2212 510 Email: info@rotabroach.co.uk Fax: +44 (0) 114 2212 563 Website: www.rotabroach.co.uk 1 Element 50 AUTO Manual Original Instructions June 2022 Thank you for purchasing our Element 50 Auto magnetic drill. We would really like your feedback on the machine. Other products by Rotabroach: Thank you for your purchase of our product. 2 Element 50 AUTO Manual Original Instructions June 2022 CONTENTS OF THE MANUAL Page 1) Intended use 4 2) General safety rules 4 3) Information plate symbols 5 4) Specification 6 5) Operational safety procedures 7 6) Operating instructions 8 7) Control panel operation 9 8) Tapping function 10 9) Gear selection 11 10) Automatic function 11 11) Magnet detection 12 12) Extension cable selection 12 13) Mounting of cutters 13 14) Remedies for hole making problems 14 15) Wiring diagram 15 16) Exploded view of machine 17 17) Exploded view of motor and gearbox 20 18) Control panel and parts list 23 19) Pipe adapter kit RD2311 24 20) Fitting the chuck 25 21) Maintenance 25 22) Trouble shooting 27 23) Cutter selection 28 24) Warranty and CE statements 29 P/N RDC4082 RDC4083 RD4152 RDC4084 CA120 RDC4086 RDC4087 RDA3105 RDC4088 RDC4089 List of Contents with Magnetic Drill Unit Stationary ring Safety belt 3mm hexagonal spanner 13mm Chuck Arbor assembly 6mm hexagonal spanner included Drift Arbor shank Safety glasses Spare brush-230V Spare brush-110V 3 Element 50 AUTO Manual Original Instructions June 2022 1) INTENDED USE The intended use of this magnetic drill is to drill holes in ferrous metals. The magnet is used to hold the drill in place whilst the drill is functioning. It is designed for use in fabrication, construction, railways, petrochemical and any other applications when drilling ferrous metal. Any deviation from its intended use will not be covered by warranty. 2) GENERAL SAFETY RULES WARNING! Read all safety warnings, instructions, illustrations, and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury. Save all warnings and instructions for future reference. The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. Work area safety Keep work area clean and well lit. Cluttered or dark areas invite accidents. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. Electrical safety a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. b) Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. f) If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock. NOTE The term "residual current device (RCD)" can be replaced by the term "ground fault circuit interrupter (GFCI)" or "earth leakage circuit breaker (ELCB)". Personal safety a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury. b) Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries. c) Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents. d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury. e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair and clothing away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts. g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards. h) Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second 4 Element 50 AUTO Manual Original Instructions June 2022 Power tool use and care a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. c) Disconnect the plug from the power source and/or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users. e) Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool's operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. g) Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation. h) Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations. Service Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained 3) INFORMATION PLATE SYMBOLS 1 2 3 4 1. Refer to the user manual for operational and safety issues regarding this machine. 2. Dispose of the machine and electrical components correctly. 3. Eye protection must be worn when operating the machine. 4. Ear defenders must be worn when operating the machine. 5 Element 50 AUTO Manual Original Instructions June 2022 4) SPECIFICATION Maximum hole cutting capacity in .2/.3C steel = 50mm dia. x 50mm deep Arbor bore = MT2 Motor Unit Voltages 110V 50-60Hz 230V 50-60Hz Normal full load 1500W 1500W Electro Magnet 56W 61W Size 200mm long 98mm wide Holding Force at 20°C with 25mm minimum plate thickness 13500N The use on any material less than 25mm thick will progressively reduce the magnetic performance. If possible, substitute material should be positioned under the magnet and work piece to equate to a suitable material thickness. If this is not possible, an alternative secure method of restraining the machine must be used. Overall Dimensions Height - maximum extended 586mm Height - minimum 450mm Width (including capstan fitting) 255mm Length Overall (including guard) 395mm Nett Weight 18.5kgs 18.5kgs Element 50/1AUTO Element 50/3AUTO Vibration total values (triax vector sum) in accordance with EN62841-1: Vibration emission value Vibration emission value (ah):3.562m/s2 (ah):3.527 m/s² Uncertainty(K):1.5m/s² Uncertainty(K):1.5m/s² Level of sound pressure in accordance with EN62841-1: Sound pressure(LpA): 87.0 dB(A) Sound pressure(LpA): 86.0 dB(A) Acoustic power(LwA): Acoustic power(LwA): 100.0 dB(A) 99.0 dB(A) Uncertainty(K)3dB(A) Uncertainty(K)3dB(A) Vibration and Noise The declared vibration total value(s) and the declared noise emission value(s) have been measured in accordance with a standard test method and maybe used for comparing one tool with another. The declared vibration total value(s) and declared noise emission values(s) may also be used in a preliminary assessment of exposure. The vibration and noise emissions during actual use of the power tool can differ from the declared total value depending on the ways in which the tool is used and especially what kind of workpiece is being processed The need to identify safety measures to protect the operator that are based on an estimation of exposure in the actual conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched off and when it is running idle in addition to the trigger time). Ear and eye defenders must be worn when operating this machine. Wear gloves to protect hands when operating the machine. These tools are UK designed and manufactured with globally sourced components and conform to the requirements of EEC Document HD.400.1 and BS.2769/84 Suitable only for a single phase 50-60Hz A.C. power supply DO NOT USE ON D.C. SUPPLY Do not use your magnetic drill on the same structure when arc welding is in progress. D.C. current will earth back through the magnet and cause irreparable damage. WARNING: THIS APPLIANCE MUST BE EARTHED! NB: ANY MODIFICATIONS TO THIS MACHINE WILL INVALIDATE THE GUARANTEE 6 Element 50 AUTO Manual Original Instructions June 2022 5) OPERATIONAL SAFETY PROCEDURES READ BEFORE USING THE MACHINE · Always take care when lifting and transporting this this machine. The maximum lifting weight for one person is 25kgs. See Fig.1 · When using electrical tools, basic safety precautions should always be followed to reduce the risk of electric shock, fire, and personal injury. · Ensure the magnet is OFF before plugging in the machine. · Do NOT use in wet or damp conditions. Failure to do so may result in personal injury. · Do NOT use in the presence of flammable liquids, gases or in high risk environments. Failure to do so may result in personal injury. · BEFORE activating the machine, inspect all electrical supply cables (including extension leads), and replace if damaged. DO NOT use if there are any signs of damage. · Only use extension cables approved for site conditions. · BEFORE activating the machine, ALWAYS check the correct function of all operational systems, switches, magnet etc. · BEFORE operating, the machine MUST be securely restrained to a fixed independent feature (by using safety strap RD4329B, or other means) to reduce the potential free movement, should the magnet become detached from the work piece. Failure to do so may result in personal injury. · ALWAYS wear approved eye protectors, ear defenders and recommended PPE at ALL times when operating the machine. · Disconnect from power source when changing cutters or working on the machine. · Cutters and swarf are sharp, ALWAYS ensure that hands are adequately protected when changing cutters or removing swarf. Use a tool or brush where necessary to remove any swarf or the cutter from the arbor. · Before operating the machine, ALWAYS ensure cutter-retaining screws are secured tightly. · Regularly clear the work area and machine of swarf and dirt, paying particular attention to the underside of the magnet base. · ALWAYS remove tie, rings, watches and any loose adornments that might entangle with the rotating machinery before operating. · ALWAYS ensure that long hair is securely enclosed by an approved restraint before operating the machine. · Should the cutter become stuck in the work piece, stop the motor immediately to prevent personal injury. Disconnect from power source and turn arbor to and from. DO NOT ATTEMPT TO FREE THE CUTTER BY SWITCHING THE MOTOR ON AND OFF. Wear safety gloves to remove the cutter from the arbor. · If the machine is accidentally dropped, ALWAYS thoroughly examine the machine for signs of damage and check that it functions correctly BEFORE resuming drilling. · Regularly inspect the machine and check for any damaged or loose parts. · ALWAYS ensure when using the machine in an inverted position that only the minimum amount of coolant is used, and that care is taken to ensure that coolant does not enter the motor unit. · Cutting tools may shatter, ALWAYS position the guard over the cutter before activating the machine. Failure to do so may result in personal injury. · On completion of the cut, a slug will be ejected. DO NOT operate the machine as the ejected slug may cause injury. · When not in use ALWAYS store the machine in a safe and secure location. · ALWAYS ensure that approved ROTABROACHTM agents conduct repairs. FIG.1 7 Element 50 AUTO Manual Original Instructions June 2022 6) OPERATING INSTRUCTIONS Keep the inside of the cutter clear of swarf. It restricts the operating depth of the cutter. · Ensure that the coolant bottle contains sufficient cutting oil to complete the required operating duration. Refill as required. · Occasionally depress the pilot to ensure cutting fluid is being correctly metered. · To start the machine, follow the control panel operation instructions. · ALWAYS switch off the motor by depressing the MOTOR stop button. DO NOT switch off the motor by depressing the MAGNET switch. · Apply light pressure when commencing the cut of a hole until the cutter is introduced into the work surface. Pressure can then be increased sufficiently to load the motor. Excessive pressure is undesirable, it does not increase the speed of penetration and will cause the safety overload protection device to stop the motor, (the motor can be restarted by operating the motor start button), and may cause excessive heat which may result in inconsistent slug ejection · Always ensure that the slug has been ejected from the previous hole before commencing to cut the next. · If the slug sticks in the cutter, move the machine to a flat surface, switch on the magnet and gently bring the cutter down to make contact with the surface. This will usually straighten a cocked slug and allow it to eject normally. · Apply a small amount of light oil lubricant regularly to the slide and arbor support bearing. · Cutter breakage is usually caused by insecure anchorage, a loosely fitting slide or a worn bearing in the arbor support. (Refer to routine maintenance instructions). · Only use approved cutting fluid, never use water diluted cutting oil. Rotabroach cutting fluid has been specially formulated to maximise the cutters performance. It is available in 1 litre (RD208) and 5 litre (RD229). Fig.2 1. Unscrew the cap 2. Pour neat oil into the coolant bottle 3. Screw the cap back on the bottle firmly 4. Open the tap. 8 Element 50 AUTO Manual Original Instructions 7) CONTROL PANEL OPERATION June 2022 CutSmartTM Technology Green Zone Perfect, try to keep in the green zone for the best cut and optimum machine performance. Yellow Zone A little too much pressure on the drill ease off to get back to the green zone. Red Zone Overload: Back off immediately as too much force will cause the motor to cut off if you continue. CutSmartTM Technology Designed for you to get the most out of your machine and your cutters. CutSmart has an easy to read panel that indicates when you are drilling with too much force, which will damage the machine and the cutters. Allow the cutter to do the work and you will find that a much smoother hole and faster drilling time is achieved. 9 Element 50 AUTO Manual Original Instructions 8) TAPPING FUNCTION June 2022 *Tapping function only to be used in manual mode* 1. Ensure power to the machine, red LED will illuminate (1). 2. Press the magnet switch on (2) to engage the magnet. The LED will light up in either green or red (3). Depending on the material thickness and magnetic adhesion. Green magnet LED indicates optimum adhesion achieved. Drilling operation is available. Warning if red magnet LED is illuminated this indicates optimum adhesion not achieved. Drilling operation is still available. 3. Use the speed controller on the top cap housing to dictate the speed, always use speeds that are recommended for the drill size being used. 4. Turn the motor on in the forward direction (4). 5. Drill the hole to the recommended tapping size for the thread to be cut. 6. Without disengaging the magnet replace the drill with the tap. 7. Set the spindle speed to the required tapping speed required. 8. Start the drill spindle in the forward direction (4) and feed the tap into the hole until it begins to cut. Once cutting the tap will feed itself through, only gentle pressure on the feed handles should be necessary. 9. Once the tap has threaded the hole the drill should be stopped immediately (4). 10. The drill spindle should then be switched to reverse (5) and the tap can be fed back out of the hole. Allowing the tap to be safely extracted from the hole at a reduced RPM. 10 Element 50 AUTO Manual Original Instructions June 2022 9) GEAR SELECTION The Element 50 magnetic drill is fitted with a 2 speed gearbox. The gear is used to reduce the output speed when using larger cutters. Slide Selector Position /\ \/ Speed Controller Setting Level 1 Level 6 200/min 500/min 100/min 265/min Slide Selector Position Up Slide Selector Positon Down 10) AUTOMATIC FUNCTION The auto feed function is an efficient way of drilling that allows for multiple units to be operated at the same time, by one operator. The Element 50 Auto can be operated both manually and with the auto feed function. The auto feed function can be used for core cutting up to 50mm x 50mm as well as twist drilling (6mm-25mm only). When operating the drill in auto feed mode, it must be set at one of the two following speeds depending on the diameter of the cutter being used. Prior to starting the machine, the electronic speed controller requires setting, if the electronic speed controller is set after starting the machine, the automatic function will not perform correctly. 11 Element 50 AUTO Manual Original Instructions June 2022 To operate the auto feed function turn on the mag drill and ensure it is set to the correct speed. With the unit turned on, push the capstan lever towards the machine. Once in place, the auto feed is activated and the spindle will begin to plunge. Once the drilling operation is completed, the spindle will automatically retract until the cutter is free from the workpiece and the machine will turn off. In the case where the spindle does not retract completely, deactivate auto feed by pulling the capstan levers into the manual position and manually retract the cutter before turning the drill off. Warning do not operate the auto feed function while tapping. 11) MAGNET DETECTION It is advised that when working on thin material a packing piece should be used to increase the material thickness under the magnet. Working on thin material without a packing piece will reduce the magnet holding force. It is advised that the drill is to be operated on ferrous material 12mm thick and above. Damage to the magnet base, such as pitting, will affect the strength of the magnet holding force. 12 Element 50 AUTO Manual Original Instructions June 2022 12) EXTENSION CABLE SELECTION The machines are factory fitted with a 3-metre length of cable having three conductors 1.5mm² LIVE, NEUTRAL and EARTH. If it becomes necessary to fit an extension cable from the power source, care must be taken in using a cable of adequate capacity. Failure to do so will result in a loss of traction by the magnet and a reduction of power from the motor. If the replacement of the supply cord is necessary, this must be done by the manufacturer or his agent in order to avoid a safety hazard. Assuming a normal AC supply of the correct voltage, it is recommended that the following extension lengths shall not be exceeded: For 110v supply: 3.5metres of 3 core x 1.5mm² For 230v supply: 26metres of 3 core x 1.5mm² ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE CHANGING CUTTERS. 13) MOUNTING OF CUTTERS The machine has been made to accept cutters having 19.05mm (3/4") dia. Weldon shanks. The following procedure is to be used when mounting cutters: Lay the machine on its side with feed handles uppermost, ensuring arbor is wound down to its lowest point to enable access to socket screws RD4066. Take appropriate pilot and place through the hole in cutter shank. Insert shank of cutter into bore of arbor, ensuring alignment of two drive flats with socket screws. Tighten both screws using hexagon key. 13 Element 50 AUTO Manual Original Instructions June 2022 14) REMEDIES FOR HOLE MAKING PROBLEMS Problem 1) Magnetic base won't hold effectively Cause Material being cut may be too thin for efficient holding. Swarf or dirt under magnet. Remedy Attach an additional piece of metal under the magnet, or mechanically clamp magnetic base to work-piece. Clean magnet. Irregularity on magnet contact or work-piece. Use extreme care; file any imperfections flush to surface. 2) Cutter skips out of centrepunch mark at initiation of cut Insufficient current going to magnet during drilling cycles. Magnetic base is not holding effectively. Worn arbor bushing and/or ejector collar. Too much feed pressure at start of cut. Confirm power supply and output from control unit, check supply cable. See causes and remedies above. New arbor bushing is needed. Light pressure only is needed until a groove is cut. The groove then serves as a stabilizer. Cutter is dull, worn, chipped or incorrectly sharpened. Replace or re-sharpen. Sharpening service is available. Poor centre-punch mark; weak pilot spring; pilot not centred in centre-punch mark. Improve centre-punch and/or replace worn parts Worn or bent pilot, worn pilot hole. Replace part or parts 3) Excessive drilling pressure required 4) Excessive cutter breakage Loose bolts on motor bushing support bracket, main casting or loose gib adjusting set screws. Incorrectly re-sharpened, worn or chipped cutter. Coming down on swarf lying on surface of workpiece. Gib strips out of adjustment or lack of lubrication. Swarf accumulated (packed) inside cutter. Steel swarf or dirt under cutter. Incorrectly re-sharpened or worn cutter. Adjust where necessary Re-sharpen or replace. Take care not to start a cut on swarf. Adjust setscrews and lubricate. Clear cutter. Remove cutter, clean part thoroughly and replace. Always have a new cutter on hand to refer to for correct tooth geometry, together with instruction sheet. Cutter skipping. See causes and remedies (2). Slide needs adjustment. Tighten grub screws supporting the slide. Cutter not attached tightly to arbor. Retighten. Insufficient use of cutting oil or unsuitable type of oil. Inject oil of light viscosity into the coolant-inducing ring and check that oil is being metered into cutter when pilot is depressed. If not, check pilot groove and arbor internally for dirt or apply oil externally. (Even a small amount of oil is very effective). 5) Excessive cutter wear Incorrect speed See cause and remedy above Incorrectly re-sharpened cutter. Insufficient or spasmodic cutting pressure. Ensure correct gear is used for the cutter. Refer to instructions and a new cutter for proper tooth geometry. Use sufficient steady pressure to slow the drill down. This will result in optimum cutting speed and chip load. 14 Element 50 AUTO Manual 15) WIRING DIAGRAM Original Instructions June 2022 No Function 1 Mains Live Input 2 Speed controller module Lead wire 3 Speed controller module Lead wire 4 Mains Neutral Input 5 Magnet Positive Output 6 Magnet Negative Output 7 Field coil Lead wire 8 Field coil Lead wire 9 Carbon brush Lead wire 10 Carbon brush Lead wire Wire Colour Brown White Red Blue 230V Red110V Blue Black Blue Green Black Brown 15 Element 50 AUTO Manual Original Instructions June 2022 No Function A Motor 'Reverse' Switch 0V B Motor 'Reverse' Switch +5V C Motor 'Forward' Switch 0V D Motor 'Forward' Switch +5V E Magnet Switch 0V F Magnet Switch +5V G Magnet 'ON' LED +5V H Magnet 'ON' LED +5V I Magnet 'ON' LED 0V J Power 'ON' LED 0V K Power 'ON' LED +5V L Motor 'Reverse' LED 0V (BLUE) M Motor 'Reverse' LED +12V (BLUE) N Motor 'Forward' LED 0V (Green) O Motor 'Forward' LED +12V (Green) Wire Colour White White White White White White White + Green White + Red White + Brown White + Black White + Brown White White White White 16 Element 50 AUTO Manual Original Instructions 16) EXPLODED VIEW OF MACHINE June 2022 17 Element 50 AUTO Manual Original Instructions June 2022 PARTS LIST Item# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Rotabroach P/N RDC4001 RD45607 RDC4002 RDC4003 RDA4201 RDB3037 RDC4004 RDG2001 RDG2002 RDC4053 RDC4054 RD4079 RDC4055 RDA4005 RDC4056 RDC4057 RDC4068 RDG3028 RDG3029 RDA4021 RDG3001 RDG4000 RDG3007 RDD4092 RDG3008 RDG4001 RDG3009 RDG3010 RDG3011 RDG3012 RDG4002 RDG4003 RDG3013 RDG4004 RDG3014 RDG4005 RDG3015 RDG4006 RDD4118 RDC4067 RD4098 RDC4060 Description Screw (Anti-loose) M5 CSK Washer Guard Support Slide Channel Screw M4×14 BTTN HD Element E40 Guard Screw M4×8 BTTN HD Motor Assembly230V Motor Assembly110V Magnet(230V) Magnet(110V) Spring Washer Screw Cable Bush Screw Nut Screw Arraying cable Power supply module set Screw M4×8 BTTN HD Side Plate Rolling Bearing 687 Gear Units Bush Motor gear Screw Clutch shaft Capstan Spindle Steel ball Clutch shaft sleeve Flat washer Rolling Bearing 6809 Clutch gear Circlip End cap Screw M4×32 BTTN HD Housing Screw M4×22 BTTN HD Screw M4×12 BTTN HD Coolant Bottle Assembly Screw Guide Bar Qty/pcs 2 2 1 1 6 1 1 1 1 1 1 4 2 1 3 3 2 1 1 6 1 2 1 2 1 4 1 1 11 1 1 1 1 1 1 10 1 4 2 1 1 2 18 Element 50 AUTO Manual Original Instructions June 2022 Item# 41 42 43 44 45 46 47 48 49 50 51 52 Rotabroach P/N RDC4061 RDA4029 RDC4104 RDF4000 RDC4065 RDA4205 RDC4066 RDA4204 RDG3016 RDC4063 RDG3017 RDG4008 53 RDA4070 54 RD4068 55 RDC4080 56 RDC4081 RDG2004 57 RDG2005 58 RD45604 59 RD4069 60 RDG3018 61 RDG3019 62 RDG3020 63 RDG3021 64 RDG3022 65 RDG3023 66 RDG4009 67 RDC4073 68 RDG3024 69 RDD4315 70 RDD4108 RDC4074 71 RDC4075 72 CA120 73 RDC4084 74 RD4152 75 RDC4083 76 RDC4082 77 RDC4086 78 RDC4087 79 RDA3105 80 RDC4088 RDC4089 81 PL2023 Description Slide Screw Spring Washer Screw Chain Nut Screw M5×12 BTTN HD Screw Chain Screw (Auti-loose) Rack Screw Cable Clamp M4 Nut Tapping screw (using 110V) Clamp (using 110V) Control Panel Assembly(230V) Control Panel Assembly(110V) Earth Lable Washer Capstan base Cover plate Capstan arbor Capstan Arm Flexible straight pin Spring Screw Screw Stepper motor Screw Handle Insert Cable Plug Assembly (230V) Cable Plug Assembly (110V) Arbor Assembly 13mm Chuck 3mm Hexagonal Spanner Safety Belt Stationary Ring Drift Arbor Shank Goggle Spare Brush(230V) Spare Brush(110V) Speed label Qty/pcs 1 2 2 10 1 2 1 2 1 6 1 2 1 4 3 1 1 1 1 1 1 1 3 3 3 3 3 2 1 4 1 1 1 1 1 1 1 2 1 1 1 1pair 1pair 1 19 Element 50 AUTO Manual Original Instructions 17) EXPLODED VIEW OF MOTOR AND GEARBOX June 2022 20 Element 50 AUTO Manual Original Instructions June 2022 PARTS LIST Item# 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 8.19 8.20 8.21 8.22 8.23 8.24 8.25 8.26 8.27 8.28 8.29 8.30 8.31 8.32 8.33 8.34 8.35 8.36 8.37 8.38 8.39 8.40 Rotabroach P/N RDC4007 RDC4008 RDC4009 RDC4010 RDC4011 RDC4012 RDB4008 RDB3030 RDC4013 RDC4014 RDC4015 RDB4004 RDB3048 RDB3046 RDB2010 RDB2022 RDB4002 RDC4016 RDC4017 RDC4018 RDC4019 RDC4020 RD45614 RM17134 RDC4021 RDC4022 RDC4023 RDC4024 RDC4025 RDC4026 RD45522 RDC4027(230V) RDC4028(110V) RD43603 RDB3069 RDC4029 RDC4030 RDC4031 RDC4032(230V) RDC4033(110V) RDC4034 RDC4035 Description Circlip Oil Seal Washer Arbor Spindle Roll Bearing Flat Key Tapping Screw Spring Gear Lever Screw Gear Box Needle Bearing Gear Shaft Washer 10mm ID Key Steel Gear Axel Gear Lever Shaft Dual Gear Washer Needle Bearing Circlip Big Gear Roll Bearing Oil Seal Straight Pin Rolling Bearing 608 Shaft Gear Flat Key Gear Oil Baffle Plate Inner Gear Plate Seal Washer Rolling Bearing 6001 Armature(230V) Armature(110V) Rolling Bearing 629 Bearing Sleeve Inductor Baffle Plate Tapping Screw Field Coil(230V) Field Coil(110V) Lead Wire Lead Wire Qty/pcs 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 21 Element 50 AUTO Manual Original Instructions June 2022 Item# 8.41 8.42 8.43 8.44 8.45 8.46 8.47 8.48 8.49 8.50 8.51 8.52 8.53 8.54 8.55 Rotabroach P/N RDC4036 RDC4037 RD33616 RDC4038(230V) RDC4039(110V) RD33614 RDC4040 RD35617 RD45613 RDC4041(230V) RDC4042(110V) RDA4035 RDC4043 RDC4044 RDA4034 RDC4045 RDC4174 Description Motor Casing Lead Wire Brush Cap Carbon Brush(230V) Carbon Brush(110V) Brush Holder Lead Wire Terminal Screw M3×6 BTTN HD Speed Controller Module(230V) Speed Controller Module(110V) Tapping Screw Top Cap Tapping Screw Tapping Screw ST2.9×8 Outlet Clamp Lead wire subassembly Qty/pcs 1 1 2 2 2 2 1 6 12 1 1 2 1 4 4 1 1 22 Element 50 AUTO Manual Original Instructions 18) CONTROL PANEL AND PARTS LIST June 2022 Item# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Rotabroach P/N RDA4051 RDC4090 RDC4091 RDC4092 RDC4093 RDA4036 RDG3025 RDG3002 RDG3000 RDC4019 RDC4099 RDA4205 RDC4100 RDC4101 RDG3026 RDG3027 Description Green Motor Switch Blue Motor Switch Magnet Switch Red LED Green LED Screw M3×12 BTTN HD Control Panel Cover Control Plate-230V Control Plate-110V Nylon Spacer Array Board M3 Nut Connection line Connection line PCBA-230V PCBA-110V Qty/pcs 1 1 1 1 1 2 1 1 1 2 1 2 1 1 1 1 23 Element 50 AUTO Manual Original Instructions June 2022 19) PIPE ADAPTOR KIT RD2311 FITTING INSTRUCTIONS · Dependent upon the size of the pipe to be cut (see illustrations) attach adjustable angle plates RD3328 with cap screws RD4325 and washers RD4205 (4 off each) to the magnet sides. Do not tighten. · Locate the machine on the centreline of the pipe taking care that the magnet is in line with the longitudinal axis of the pipe. · Switch on the magnet and move the sliding plates down to the outside diameter of the pipe. Tighten the screws on both sides by hand then check once again that the full length of the moving plates is touching the pipe at the front and back, fasten the plate securely. Feed the safety strap through the lugs at the front of the housing, around the pipe and pull tight. · When cutting the hole DO NOT use excessive pressure but rather let the cutter ease into the cutting surface. 24 Element 50 AUTO Manual Original Instructions June 2022 20) FITTING THE CHUCK · The machine comes supplied with an RDC4087 (Arbor Shank) & RDC4084 (13mm Chuck). · Insert RDC4087 into RDC4009 (Arbor Spindle), ensure a good and tight fit is achieved. · Insert RD4084 into RDC4087, ensure a good and tight fit is achieved. · Replacing the chuck is the reverse sequence, by utilising RDC4086 (Drift). 21) MAINTENANCE In order to `get the best life' out of your Rotabroach machine always keep it in good working order. A number of items must always be checked on Rotabroach machines. Always before starting any job make sure the machine is in good working order and that there are no damaged or loose parts. Any loose parts must be tightened. Before proceeding with any maintenance work be certain that the power supply is disconnected. Description Visual check of machine for damage Operation of machine Check brush wear Check magnetic base Check alignment of the machine Check grease Check armature Every operation X X X 1 week 1 Month X X X X Visually check the machine for damage. The machine must be checked before operation for any signs of damage that will affect the operation of the machine. Particular notice must be taken to the mains cable, if the machine appears to be damaged it should not be used, failure to do so may cause injury or death. Check operation of the machine. The machines operation must be checked to ensure that all components are working correctly. Machine Brushes Should be checked to make sure there is no abnormal wear present (this should be checked at least once a week if used frequently). If the brush has worn more than 2/3 of the original length, the brushes should be changed. Failure to do so may cause damage to the machine. 25 Element 50 AUTO Manual Original Instructions June 2022 Magnetic base Before every operation the magnetic base should be checked to make sure that the base is flat and there is no damage present. An uneven magnet base will cause the magnet not to hold as efficiently and may cause injury to the operator. Adjustment of slide and bearing bracket alignment. An essential requirement of the machine is that the slide can move in a smooth and controlled manner, free of lateral movement and vibration. This situation can be maintained by periodic adjustment of the slide and is accomplished in the following manner: 1. Place the machine in an upright position and, by means of the capstan, raise the slide to its highest position. Clean the brass gib strips and apply a small amount of light machine oil to the wear surfaces. 2. Now lower the slide back to its lowest position. Bring the slide into the center of the dovetail slide housing and loosen screws thus allowing free movement of the arbor support bracket. 3. Commencing with the middle screws, gently feed in all the screws until slight resistance is encountered. 4. Operate the slide up and down a few times to test the movement and make any further necessary adjustments. Try to ensure that all the screws are exerting a uniform pressure on the slide from top to bottom. A perfectly adjusted slide will operate freely up and down without any sideways movement. 5. Now raise the slide to its highest position. Slightly undo the arbor bearing bracket and, using fingers only, tighten the screws. 6. Place the machine on a steel plate, connect to power supply and switch on the magnet. Start up the motor. If the arbor is incorrectly aligned, the arbor support bracket will be seen to oscillate. Make any necessary further adjustments to the bracket to ensure correct alignment of the spindle and finally tighten the screws using a spanner. Lastly tighten the arbor bearing bracket. Check machines grease. The gearbox grease should be checked once a month to ensure all moving components are covered to prevent wear. The grease should be changed at least once a year to ensure you gain the best from your machine. Check Armature of the machine. This should be checked at least once a month to check that there are no visual signs of damage to the body or to the commutator. Some signs of wear will be seen on the commutator over a period of time but this is normal (this is the part that comes into contact with the brushes) however, if there are any signs of abnormal damage the part should be replaced. 26 Element 50 AUTO Manual Original Instructions June 2022 22) TROUBLE SHOOTING 21) MAINTENANCE Magnet and motor do not function Magnet does function, the motor does not Magnet does not function, the motor does Hole cutters break quickly, holes are bigger than the hole cutter Motor running roughly and/or seizing up Motor making a rattling sound Motor humming, big sparks and motor has no force Motor does not start or fails. Guiding takes a great deal of effort Insufficient magnetic force Frame under voltage Fuse blows when magnet switch is turned on Fuse blows when motor is started up Rotation system free stroke too long - The magnet switch is not connected to the power supply - Damaged or defective wiring - Defective fuse - Defective magnet switch - Defective control unit - Defective power supply - Damaged or defective wiring - Carbon brushes are stuck or worn out - Defective magnet switch - Defective on / off switch - Defective control unit - Defective armature and/or field - Defective protective reed switch - Defective magnet - Defective fuse - Defective control unit - Play in the guide - Bent spindle - Shaft extending from the motor is bent - Pilot bent - Bent spindle - Shaft extending from the motor is bent - Triangular guide not mounted straight - Dirt between spindle and triangular guide - Gear ring (bottom of the armature) worn out - Gear(s) worn out - No grease in gear box - Armature damaged - Field burned - Carbon brushes worn out - Damaged or defective wiring - Damage to armature or field coil - Damaged or defective brushes - Guide is set too tight - Guide is dry - Guide/gear- rack/rotation system is dirty or damaged - Damaged or defective wiring - Bottom of magnet not clean and dry - Bottom of magnet not flat - Work piece is not bare metal - Work piece is not flat - Work piece is too thin less than 10mm - Defective control unit - Defective magnet - Damaged / defective wiring - Defective magnet - Motor seriously dirty - Damaged or defective wiring - Wrong value fuse - Defective magnet switch - Defective control unit - Defective magnet - Damaged or defective wiring - Wrong value fuse - Motor running roughly - Defective armature and / or field - Carbon brushes worn out - Defective control unit - Loose or defective gear-rack - Defective rotation system 27 Element 50 AUTO Manual Original Instructions 23) CUTTER SELECTION Material Mild and free cutting steels Mild and free cutting steels Steel angle and joists Steel angle and joists Plate and sheet steel Plate and sheet steel Aluminium Aluminium Brass Brass Cast iron Cast iron Stainless steel Stainless steel Stainless steel Rail track Tool steel Die Steel Cast Iron Inox Inconel Fine Grain Steel Hardox Material Hardness <900N/mm² <900N/mm² <900N/mm² <900N/mm² <900N/mm² <900N/mm² <900Nmm² <900N/mm² <900N/mm² <900N/mm² <900N/mm² <900N/mm² <900N/mm² <900N/mm² >1400N/mm² >1400N/mm² >1400N/mm² >1400N/mm² >1800N/mm² >1800N/mm² >1800N/mm² >1800N/mm² >1800N/mm² June 2022 Cutter RAP or RAPL SRCV or SRCVL RAP or RAPL SRCV or SRCVL RAP or RAPL SRCV or SRCVL RAP or RAPL SRCV or SRCVL RAP or RAPL SRCV or SRCVL RAP or RAPL SRCV or SRCVL RAP or RAPL SRCV or SRCVL CWC to CWCX SCRWC or SCRWCL CWC to CWCX CWC to CWCX CTCT CTCT CTCT CTCT CTCT 28 Element 50 AUTO Manual Original Instructions June 2022 24) WARRANTY AND CE STATEMENTS RotabroachTM warrants its machines to be free from faulty parts, under normal usage of machines, for a period of 12 months from initial date of purchase. All other parts (excluding cutters) are under warranty for 90 days, provided that the warranty registration card (or online registration) has been completed and returned to RotabroachTM or its designated distributor within a period of (30) days from the purchase date. Failure to do so will void the warranty. If the stated is adhered to, RotabroachTM will repair or replace (at its option) without charge any faulty items returned. This Warranty does not cover: 1. Components that are subject to natural wear and tear caused by the use is not in accordance with the operator's instructions 2. Defects in the tool caused by non-compliance with the operating instructions, improper use, abnormal environment conditions, inappropriate operating conditions overload or insufficient servicing or maintenance. 3. Defects caused by using accessories, components or spare parts other than original RotabroachTM parts. 4. Tools to which changes or additions have been made. 5. Electrical components are subject to manufacturer's warranty. Your online registration can be submitted at www.rotabroach.co.uk The warranty claim must be logged within the warranty period. This requires the submission or sending of the complete tool in question with the original sales receipt which must indicate the purchase date of the product. A complaint form must also be submitted prior to the return. This can be found online at www.rotabroach.co.uk. Failure to complete this form will result in the delay of your claim. All goods returned defective must be returned pre-paid to RotabroachTM, in no event shall RotabroachTM be liable for subsequent direct, or indirect loss or damage. THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, (EXPRESSED OR IMPLIED) INCLUDING ANY WARRANTY OF MERCHANTABLITY OR FITNESS FOR A PARTICULAR PURPOSE. ROTABROACHTM RESERVE THE RIGHT TO MAKE IMPROVEMENTS AND MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE Known and Trusted Worldwide for Quality, Performance and Reliability 29 Element 50 AUTO Manual Original Instructions June 2022 EC Declaration of Conformity Based on the referenced test reports, the below product has been found to comply with the relevant harmonised standard(s) to the directive(s) listed on this verification at the time the tests were carried out. Name and address of manufacturer: Rotabroach Ltd Burgess Road, Sheffield Road, Sheffield S9 3WD, United Kingdom Product tested: ELEMENT 50/1 AUTO ELEMENT 50/3 AUTO Application of product: Hole drilling metal Relevant standards/directives EN127172001+A12009 The EMC Directive 2014/30/EU The Machinery Directive 2006/42/EC Annex I EN 62841-1:2015 +AC:15 EN IEC55014-1:2021 EN IEC55014-2:2021 EN IEC61000-3-2: 2019+A1:2021 EN61000-3-3:2013+A1:2019+A2:2021 Name and Address of Responsible person. Date: 28th July 2020 Mr Mathew Grey Managing Director Burgess Road, Sheffield S9 3WD United Kingdom Signature: 30