Rotabroach Element 40 PERM Magnetic Drilling Machine

Model Numbers: Element40/1PERM & Element40/3PERM

Introduction

This manual provides comprehensive information for the Rotabroach Element 40 PERM magnetic drilling machine. It covers intended use, safety rules, specifications, operational procedures, maintenance, troubleshooting, and warranty details.

The machine is designed for drilling holes in ferrous metals using its magnetic base for stability. It is suitable for fabrication, construction, railways, and petrochemical applications.

Manufacturer: Rotabroach Ltd, Burgess Road, Sheffield Road, Sheffield, S9 3WD, United Kingdom.

Contact: Tel: +44 (0) 114 2212 510, Email: info@rotabroach.co.uk, Website: www.rotabroach.co.uk

General Safety Rules

WARNING: Read all safety warnings, instructions, illustrations, and specifications. Failure to follow instructions may result in electric shock, fire, and/or serious injury.

Keep the work area clean and well lit.
Do not operate power tools in explosive atmospheres.
Keep children and bystanders away.
Ensure power tool plugs match the outlet.
Avoid body contact with earthed surfaces.
Do not expose power tools to rain or wet conditions.
Do not abuse the cord.
When operating outdoors, use an extension cord suitable for outdoor use.
In damp locations, use a residual current device (RCD) protected supply.
Stay alert and use common sense.
Use personal protective equipment (eye protection, dust mask, safety shoes, hard hat, hearing protection).
Prevent unintentional starting. Ensure the switch is OFF before connecting to power or picking up the tool.
Remove any adjusting key or wrench before turning the power tool on.
Do not overreach; maintain proper footing and balance.
Dress properly; avoid loose clothing, jewelry, and keep hair away from moving parts.
Ensure dust extraction facilities are connected and properly used.
Do not let familiarity lead to complacency.
Use the correct power tool for the application.
Do not use a power tool if the switch does not operate correctly.
Disconnect from power source before making adjustments or changing accessories.
Store idle power tools out of reach of children.
Maintain power tools; check for misalignment or binding of moving parts.
Keep cutting tools sharp and clean.
Use power tools, accessories, and tool bits in accordance with instructions.
Keep handles and grasping surfaces dry, clean, and free from oil and grease.
Have power tools serviced by a qualified repair person using identical replacement parts.

Information Plate Symbols:

Symbol 1: Refer to the user manual for operational and safety issues.
Symbol 2: Dispose of the machine and electrical components correctly.
Symbol 3: Eye protection must be worn.
Symbol 4: Ear defenders must be worn.

Specifications

Maximum hole cutting capacity: 40mm dia. x 50mm deep in .2/.3C steel.
Arbor bore: 19.05mm (3/4") dia.

Motor Unit

	110V 50-60Hz	230V 50-60Hz
Voltages	110V 50-60Hz	230V 50-60Hz
Normal full load	1200 W	1200 W
Size	210mm long, 90mm wide
Holding Force at 20°C with 25mm minimum plate thickness	5000N

Note on Material Thickness: Using materials less than 25mm thick will reduce magnetic performance. Substitute material or use an alternative secure method of restraining the machine.

Overall Dimensions

Height - maximum extended: 530mm
Height - minimum: 450mm
Width (including Capstan fitting): 185mm
Length Overall (including Guard): 394mm
Nett Weight: 13kgs

Vibration and Noise

	Element 40/1PERM	Element 40/3PERM
Vibration emission value (a_h,CW) in accordance with EN62841-1:	2.74 m/s² (Uncertainty K: 1.5 m/s²)	2.46 m/s² (Uncertainty K: 1.5 m/s²)
Level of sound pressure in accordance with EN62841-1:	90.6 dB(A) (Uncertainty K: 3dB(A))	89.6 dB(A) (Uncertainty K: 3dB(A))
Acoustic power (L_wA):	103.6 dB(A)	102.6 dB(A)

Vibration and noise emissions during use may differ from declared values based on usage conditions. Operators should be aware of exposure levels and implement safety measures.

Ear and eye defenders, and gloves must be worn when operating the machine.

This product is UK designed and manufactured with globally sourced components and conforms to 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.

WARNING: Do not use the magnetic drill on the same structure when arc welding is in progress, as D.C. current can cause irreparable damage. The appliance must be EARTHED. Any modifications will invalidate the guarantee.

Operational Safety Procedures

Always take care when lifting and transporting the machine. Maximum lifting weight for one person is 25kgs.
Ensure the magnet is OFF before plugging in the machine.
Do NOT use in wet or damp conditions or in the presence of flammable liquids, gases, or in high-risk environments.
Inspect all electrical supply cables and replace if damaged.
Only use extension cables approved for site conditions.
Always check the correct function of all operational systems, switches, and the magnet.
Securely restrain the machine to a fixed independent feature using a safety strap before operating.
ALWAYS wear approved eye protectors, ear defenders, and recommended PPE.
Disconnect from power source when changing cutters or working on the machine.
Protect hands when changing cutters or removing swarf. Use a tool or brush if necessary.
Ensure cutter-retaining screws are secured tightly.
Regularly clear the work area and machine of swarf and dirt.
Remove jewelry and tie hair back before operating.
Ensure long hair is securely enclosed.
If the cutter becomes stuck, stop the motor immediately, disconnect from power, and try to free the cutter.
If the machine is accidentally dropped, examine for damage and check function before resuming.
Regularly inspect the machine for damaged or loose parts.
When using in an inverted position, use minimum coolant and prevent it from entering the motor unit.
Position the guard over the cutter before activating the machine.
Do not operate the machine after a cut until the slug has been ejected.
Store the machine in a safe and secure location when not in use.
Ensure repairs are conducted by approved Rotabroach™ agents.

Operating Instructions

Keep the inside of the cutter clear of swarf.
Ensure the coolant bottle contains sufficient cutting oil. 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.
Apply light pressure when commencing a cut until the cutter is introduced into the work surface. Increase pressure as needed, but avoid excessive pressure which can overload the motor.
Always ensure the slug has been ejected before commencing the next cut.
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 to straighten and eject the slug.
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 arbor support bearing.
Only use approved cutting fluid. Rotabroach cutting fluid is recommended.

Coolant Bottle Instructions:

Unscrew the cap.
Pour neat oil into the coolant bottle.
Screw the cap back on the bottle firmly.
Open the tap.

Control Panel Operation

The control panel features:

Magnet ON: Move the mechanical magnet switch to the ON position. The LED will light up red or green depending on magnetic adhesion.
Motor Switch: When the magnet is ON, the GREEN switch lights up, indicating the motor is ready to start.
Motor ON: Press the GREEN Switch to turn the motor on.
Cutting: Monitor the CutSmart™ visual indicator for optimal pressure.
Motor OFF: Press the RED switch to stop the motor. The GREEN switch will turn on.

CutSmart™ Technology:

This system indicates drilling pressure:

Green Zone: Optimal pressure for best cut and machine performance.
Yellow Zone: Slightly too much pressure; ease off to return to the green zone.
Red Zone: Overload; back off immediately to prevent damage to the machine and cutters.

CutSmart™ helps you get the most out of your machine and cutters by indicating when too much force is applied.

Gear Selection

The Element 40 PERM has a 2-speed gearbox to reduce output speed for larger cutters.

Gear position 1 (High speed): For cutters up to 30mm diameter.
Gear position 2 (Low speed): For cutters 30-40mm diameter.

Extension Cable Selection

The machine is fitted with a 3-metre, 1.5mm² cable. If an extension cable is required:

Ensure it has adequate capacity to maintain magnet traction and motor power.
For 110v supply: Do not exceed 3.5 metres of 3 core x 1.5mm².
For 230v supply: Do not exceed 26 metres of 3 core x 1.5mm².

ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE CHANGING CUTTERS.

Mounting of Cutters

The machine accepts cutters with 19.05mm (3/4") dia. Weldon shanks.

Lay the machine on its side with feed handles uppermost, arbor wound down to its lowest point.
Take appropriate pilot and place through the hole in the cutter shank.
Insert the cutter shank into the arbor bore, aligning the drive flats with the socket screws.
Tighten both screws using the hexagon key.

Capstan Operation

The quick-release capstan allows for simple dual-side operation.

To remove the capstan:

Press the central button on the capstan hub and hold the capstan arms.
With the button pressed, pull the capstan away from the main body.
Re-insert the hexagonal shaft into the hexagonal slot to attach the capstan.

Remedies for Hole Making Problems

Problem	Cause	Remedy
1) Magnetic base won't hold effectively	Material being cut may be too thin. Swarf or dirt under magnet. Irregularity on magnet contact or work-piece. Insufficient current to magnet. Magnetic base not holding effectively.	Attach additional metal under magnet, or clamp magnetically. Clean magnet. File imperfections flush to surface. Confirm power supply and output. Check supply cable. See causes and remedies above.
2) Cutter skips out of centre-punch mark at initiation of cut	Worn arbor bushing/ejector collar. Too much feed pressure. Cutter is dull, worn, chipped, or incorrectly sharpened. Poor centre-punch mark; weak pilot spring; pilot not centered. Worn or bent pilot. Loose bolts on motor bushing support bracket, main casting, or gib adjusting set screws. Incorrectly re-sharpened, worn, or chipped cutter.	New arbor bushing needed. Light pressure until groove is cut. Replace or re-sharpen. Improve centre-punch and/or replace worn parts. Replace part or parts. Adjust where necessary. Re-sharpen or replace.
3) Excessive drilling pressure	Loose bolts on motor bushing support bracket, main casting, or loose gib adjusting set screws. Incorrectly re-sharpened, worn, or chipped cutter.	Adjust where necessary. Re-sharpen or replace.
4) Excessive cutter breakage	Coming down on swarf. Gibs out of adjustment or lack of lubrication. Swarf accumulated inside cutter. Swarf or dirt under cutter. Incorrectly re-sharpened or worn cutter. Cutter skipping. Slide needs adjustment. Cutter not attached tightly to arbor. Insufficient use of cutting oil or unsuitable type of oil. Incorrect speed.	Take care not to start cut on swarf. Adjust setscrews and lubricate. Clear cutter. Remove cutter, clean, and replace. Refer to instruction sheet for correct tooth geometry. See causes and remedies (2). Tighten grub screws. Retighten. Inject light oil into coolant ring; check pilot groove and arbor for dirt. Ensure correct gear is used.
5) Excessive cutter wear	See cause and remedy above. Incorrectly re-sharpened cutter. Insufficient or spasmodic cutting pressure.	Refer to instructions and new cutter for proper tooth geometry. Use sufficient steady pressure to slow the drill down.

Wiring Diagram

The control board has connections for mains input/output and motor output.

Control Board Connections:

1: Mains Neutral Input (Blue)
2: Motor Neutral Output (Black)
3: Motor Live Output (Red)
4: Mains Live Input (Brown)

Display Board Connections:

A: Motor 'Stop' Switch OV (White)
B: Motor 'Stop' Switch +5V (White)
C: Motor 'Start' Switch OV (White)
D: Motor 'Start' Switch +5V (White)
E, F: N/A
G: Magnet 'ON' LED +5V (White + Green)
H: Magnet 'ON' LED +5V (White + Red)
I: Magnet 'ON' LED OV (White + Brown)
J, K: N/A
L: Motor 'Stop' LED OV (Red) (White)
M: Motor 'Stop' LED +12V (Red) (White)
N: Motor 'Start' LED OV (Green) (White)
O: Motor 'Start' LED +12V (Green) (White)

Exploded Views

Detailed exploded views of the machine, motor, and gearbox are provided for parts identification and assembly reference.

Exploded View of Machine: Shows all external components and their assembly.

Exploded View of Motor and Gearbox: Details internal components of the motor and gearbox assembly.

Parts List

A comprehensive parts list is provided, detailing Rotabroach P/N, Description, and Quantity/pcs for all components of the machine.

Control Panel and Parts List

The control panel consists of:

Red Motor Switch (RDA4052)
Green Motor Switch (RDA4051)
Green LED (RDC4093)
Screw M3 X 12 BTTN HD (RDA4036)
Control Panel Cover (RDB3121)
Control Plate (RDB3100PERM / RDB3101PERM)
Nylon Spacer (RDA4019)
Array Board (RDC4099)
M3 Nut (RDA4205)
Connection line (RDA4083, RDB4010)

Fitting the Chuck

To remove the arbor:

Lay the machine on its side.
Unscrew the two grub screws at the top of the arbor.
Remove the arbor once detached from the spindle.
Remove the arbor support bracket and guard with the arbor retained.
Mount the chuck using the chuck adapter RD33153.
Replacing the chuck is the reverse sequence.

Maintenance

Regular maintenance ensures optimal performance and longevity of the Rotabroach machine.

Before starting any job: Ensure the machine is in good working order, with no damaged or loose parts.

Before performing maintenance: Ensure the power supply is disconnected.

Description	Every operation	1 week	1 Month
Visual check of machine for damage	X
Operation of machine	X
Check brush wear		X
Check magnetic base	X
Check alignment of the machine	X
Check grease			X
Check armature			X

Visual check for damage: Inspect for any damage affecting operation, particularly the mains cable. Do not use if damaged.

Check operation of the machine: Ensure all components are working correctly.

Machine Brushes: Check for abnormal wear at least weekly. Replace if worn more than 2/3 of the original length.

Magnetic base: Check for flatness and damage before every operation. An uneven base reduces holding efficiency.

Adjustment of slide and bearing bracket alignment:

Place machine upright, raise slide to highest position. Clean gib strips and apply light machine oil.
Lower slide to lowest position, center in housing, loosen screws for free movement of arbor support bracket.
Gently tighten screws, starting with the middle ones, until slight resistance is encountered.
Operate slide up and down to test movement and make adjustments for uniform pressure.
Raise slide to highest position. Slightly undo arbor bearing bracket and tighten screws.
Place machine on steel plate, connect power, switch on magnet, and start motor. Adjust bracket for correct spindle alignment if arbor oscillates. Tighten screws.

Check machines grease: Check gearbox grease monthly; change at least annually.

Check Armature: Check monthly for visual signs of damage to the body or commutator. Some commutator wear is normal.

Trouble Shooting

Problem	Possible Cause	Remedy
Magnet and motor do not function	Damaged/defective wiring, defective fuse, defective magnet switch, defective control unit, defective power supply.	Check wiring, fuse, magnet switch, control unit, and power supply.
Magnet functions, motor does not	Damaged/defective wiring, carbon brushes stuck/worn, defective magnet switch, defective control unit, defective armature/field, defective protective reed switch, defective magnet.	Check wiring, carbon brushes, magnet switch, control unit, armature/field, reed switch, and magnet.
Magnet does not function, motor does	Defective magnet.	Check/replace magnet.
Hole cutters break quickly, holes are bigger than the cutter	Play in guide, bent spindle, bent pilot, triangular guide not mounted straight, dirt between spindle and guide, worn gear ring, worn gears, no grease in gearbox, damaged armature, burned field, worn carbon brushes.	Check guide, spindle, pilot, and cleanliness. Lubricate gearbox. Check armature, field, brushes.
Motor running roughly and/or seizing up	Damaged/defective wiring, damage to armature/field coil, damaged/defective brushes.	Check wiring, armature/field coil, and brushes.
Motor making a rattling sound	Gear ring (bottom of armature) worn out, gears worn out, no grease in gearbox.	Check gear ring, gears, and gearbox lubrication.
Motor humming, big sparks, motor has no force	Armature damaged, field burned, carbon brushes worn out, damaged/defective wiring, damage to armature or field coil, damaged/defective brushes.	Check armature, field, brushes, wiring, and coils.
Motor does not start or fails.	Damaged/defective wiring, damage to armature or field coil, damaged/defective brushes.	Check wiring, armature/field coil, and brushes.
Guiding takes a great deal of effort	Guide is set too tight, guide is dry, guide/gear-rack/rotation system is dirty or damaged.	Adjust guide, lubricate, or clean/repair system.
Insufficient magnetic force	Bottom of magnet not clean/dry, bottom of magnet not flat, workpiece not bare metal, workpiece not flat, workpiece too thin (<10mm).	Clean magnet. Ensure workpiece is flat and suitable.
Frame under voltage	Defective control unit.	Check/replace control unit.
Fuse blows when magnet switch is turned on	Damaged/defective wiring, defective magnet switch.	Check wiring and magnet switch.
Fuse blows when motor is started up	Damaged/defective wiring, wrong value fuse, defective magnet switch, defective control unit, defective magnet.	Check wiring, fuse value, magnet switch, control unit, and magnet.
Rotation system free stroke too long	Damaged/defective wiring, defective armature/field, worn carbon brushes, defective control unit, loose or defective gear-rack, defective rotation system.	Check wiring, armature/field, brushes, control unit, gear-rack, and rotation system.

Cutter Selection and Speeds

Material hardness and cutter type influence the required cutting speed and feed rate.

Material Hardness & Cutter Type:

Material	Material Hardness	Cutter
Mild and free cutting steels	<700N/mm²	RAP or RAPL
Mild and free cutting steels	<850N/mm²	SRCV or SRCVL
Steel angle and joists	<700N/mm²	RAP or RAPL
Steel angle and joists	<850N/mm²	SRCV or SRCVL
Plate and sheet steel	<700N/mm²	RAP or RAPL
Plate and sheet steel	<850N/mm²	SRCV or SRCVL
Aluminium	<750N/mm²	RAP or RAPL
Aluminium	<850N/mm²	SRCV or SRCVL
Brass	<700N/mm²	RAP or RAPL
Brass	<850N/mm²	SRCV or SRCVL
Cast iron	<700N/mm²	RAP or RAPL
Cast iron	<850N/mm²	SRCV or SRCVL
Stainless steel	<700N/mm²	RAP or RAPL
Stainless steel	<850N/mm²	SRCV or SRCVL
Stainless steel	>850N/mm²	CWC to CWCX
Rail track	>850N/mm²	SCRWC or SCRWCL
Tool steel	>850N/mm²	CWC to CWCX
Die Steel	>850N/mm²	CWC to CWCX

Cutting Speed (RPM) by Cutter Diameter and Material:

Material to be cut	Cutter diameter (mm)	RPM Relationship
	13	14	18	22	30	50	65
Aluminium	L	U	L	U	L	U	L	U	L	U	L	U
Lower Speed	60-90	1469	2203	1364	2046	1061	1591	868	1302	637	955	382	573	294	441
Brass & Bronze	40-50	979	1224	909	1137	707	884	579	723	424	530	255	318	196	245
Iron: cast (soft)	30-50	734	1224	682	1137	530	884	434	723	318	530	191	318	147	245
Iron: cast (hard)	15-21	367	514	341	477	265	371	217	304	159	223	95	134	73	103
Iron: cast (malleable)	15-30	588	734	546	682	424	530	347	434	255	318	153	191	118	147
Steel: mild	24-30	734	1224	682	1137	530	884	434	723	318	530	191	318	147	245
high tensile	3-5	73	122	68	114	53	88	43	72	32	53	19	32	15	24
stainless (free cutting)	15-18	367	441	341	409	265	318	217	260	159	191	95	115	73	88
stainless (heat resisting)	6-13	26	318	136	296	106	230	87	188	64	138	38	83	29	64

Feed Per Tooth (mm):

Material or Application Type	Feed Per Tooth (mm)
Thin Walled Workpieces, Oblique Entry/ Curved Surfaces, Semi-Circles / Fragile Setups	.0254/.0508 (.0762 FPT with Work Hardening Materials)
Soft/Gummy Materials	.1016/.127
Typical/Average Applications	.0762/.1016
Deep Holes	.1016/.127

Difficult-to-machine materials may require reduced feed rates.

Warranty and CE Statements

Warranty: Rotabroach warrants machines for 12 months from the date of purchase against faulty materials under normal usage. Other parts have a 90-day warranty if the registration card is completed and returned within 30 days.

Warranty does not cover: Natural wear and tear, misuse, non-compliance with operating instructions, use of non-Rotabroach parts, unauthorized modifications, or electrical components (subject to manufacturer's warranty).

To claim warranty, log the claim within the warranty period, submit the complete tool with the original sales receipt, and a complaint form. Return goods pre-paid to Rotabroach™.

EC Declaration of Conformity:

Based on referenced test reports, the product complies with relevant harmonised standards and directives at the time of testing.