Carbatec RT-RPU2400 User manual

RT-RPU2400 MANUAL
Variable Speed
Router Power Unit
CARBATEC.COM.AU

FOR TECHNICAL SUPPORT CALL 1800 658 111
RT-RPU2400
THANK YOU
FOR CHOOSING
Carbatec has been a trusted brand for woodworking enthusiasts
and professionals across Australia and New Zealand, since 1987.
Our quality woodworking products are designed and built to oer
value and performance, making the latest features and technological
advancements more accessible to Aussie woodworkers.
Backed by our no-fuss after-sales care and warranty support,
you can trust Carbatec to keep you woodworking, as promised.
We look forward to sharing in your woodworking journey!
If you have any questions about our products or service,
please call us on 1800 658 111 or email us at [email protected]
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V. 1
2

CARBATEC.COM.AU
RT-RPU2400 WELCOME
WHAT’S IN THE BOX
RT-RPU2400
VARIABLE SPEED ROUTER POWER UNIT
Fig. 1
A. Main Body
B. ¼" Collet Nut
C. ½" Collet Nut
D. Collet Spanners (x2)
3
D
D
The following items are provided
in the shipping box:
A
B
C

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RT-RPU2400
SERIAL NUMBER:
DATE OF PURCHASE:
Record the serial number and date of purchase
in your manual for future reference.
Key information can be found
on the inspection panel, found
on the rear of the machine.
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RT-RPU2400
CONTENTS
Introduction 2
What’s in the box 3
Key information 4
Safety instructions - General 6-9
Safety instructions - Router Power Unit 10-11
Safety instructions - Electrical 12-13
Overview & Specications 14
Assembly 15-19
Operation 20
Maintenance & Cleaning 21
Table Installation 23
Parts diagram 24
Parts list 25
Warranty details 27
CONTENTS
5

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IMPORTANT! Safety is the single most important consideration in the operation of this
equipment. The following instructions must be followed at all times. Failure to follow all
instructions listed below may result in electric shock, re, and/or serious personal injury.
There are certain applications for which this tool was designed. We strongly recommend that
this tool not be modied and/or used for any other application other than that for which it was
designed. If you have any questions about its application, do not use the tool until you have
contacted us and we have advised you.
The purpose of safety symbols is to attract your attention to possible dangers. The safety
symbols and the explanations with them deserve your careful attention and understanding.
The symbol warnings do not, by themselves, eliminate any danger. The instructions and
warnings they give are no substitutes for proper accident prevention measures.
!
Be sure to read and understand all safety instructions in this manual, including all safety
alert symbols such as “DANGER,” “WARNING,” and “CAUTION” before using this tool.
Failure to following all instructions listed below may result in electric shock, re, and/or
serious personal injury.
A safety alert symbol Indicates DANGER, WARNING, or CAUTION.
May be used in conjunction with other symbols or pictographs.
Indicates an imminently hazardous situation, which, if not avoided,
will result in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided,
could result in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided,
could result in minor or moderate injury.
(Without Safety Alert Symbol) Indicates a situation that may result
in property damage.
SAFETY INSTRUCTIONS
!
!
SYMBOL MEANING
!!
Carbatec products bearing the Regulatory Compliance Mark (RCM) have been tested in
accordance with applicable Australian/New Zealand Standards to ensure their compliance
with all mandatory standards and regulations (applicable at time of original sale). Carbatec
Pty Ltd are registered as a responsible supplier with relevant Australian government
departments and our products are registered on the EESS & ACMA database.
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RT-RPU2400
Operating a power tool can be dangerous
if safety and common sense are ignored.
The operator must be familiar with the
operation of this machine. Read this manual
to understand this machine. DO NOT operate
this machine if you do not fully understand the
limitations of this tool. DO NOT modify this
machine in any way.
BEFORE USING
THIS MACHINE
!
To avoid serious injury and damage to the
tool, read and follow all of the Safety and
Operating Instructions before operating
the machine.
!
1. Some dust created by using power tools
contains chemicals to cause cancer, birth
defects, or other reproductive harm.
Some examples of these chemicals are:
• Lead from lead-based paints.
• Crystalline silica from bricks,
cement, and other masonry
products.
• Arsenic and chromium from
chemically treated lumber
Your risk from these exposures varies,
depending on how often you do this
type of work. To reduce your exposure to
these chemicals: work in a well ventilated
area and work with approved safety
equipment, such as those dust masks
that are specially designed to lter out
microscopic particles.
2. READ the entire Owner’s Manual.
LEARN how to use the tool for its
intended applications.
3. GROUND ALL TOOLS. If the tool is
supplied with a 3-prong plug, it must
be plugged into a 3-contact electrical
receptacle. The 3rd prong is used to
ground the tool and provide protection
against accidental electric shock.
4. AVOID A DANGEROUS WORKING
ENVIRONMENT. DO NOT use electrical
tools in a damp environment or expose
them to rain.
5. DO NOT use electrical tools in the
presence of ammable liquids or gasses.
6. ALWAYS keep the work area clean, well
lit, and organized. DO NOT work in an
environment with oor surfaces that are
slippery from debris, grease, and wax.
7. KEEP VISITORS AND CHILDREN AWAY.
DO NOT permit people to be in the
immediate work area, especially when the
electrical tool is operating.
8. DO NOT FORCE THE TOOL to perform
an operation for which it was not
designed. It will do a safer and higher
quality job by only performing operations
for which the tool was intended.
GENERAL SAFETY
SAFETY INSTRUCTIONS
7

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9. WEAR PROPER CLOTHING.
DO NOT wear loose clothing, gloves,
neckties, or jewelry. These items can
get caught in the machine during
operations and pull the operator into
the moving parts. The user must wear
a protective cover on their hair, if the
hair is long, to prevent it from contacting
any moving parts.
10. CHILDPROOF THE WORKSHOP AREA
by removing switch keys, unplugging
tools from the electrical receptacles,
and using padlocks.
11. ALWAYS UNPLUG THE TOOL FROM
THE ELECTRICAL RECEPTACLE
when making adjustments, changing
parts or performing any maintenance.
12. KEEP PROTECTIVE GUARDS IN
PLACE AND IN WORKING ORDER.
13. AVOID ACCIDENTAL STARTING. Make
sure that the power switch is in the
“OFF” position before plugging in the
power cord to the electrical receptacle.
14. REMOVE ALL MAINTENANCE TOOLS
from the immediate area prior to turning
“ON” the machine.
15. USE ONLY RECOMMENDED
ACCESSORIES. Use of incorrect or
improper accessories could cause
serious injury to the operator and cause
damage to the tool. If in doubt, check
the instruction manual that comes with
that particular accessory.
16. NEVER LEAVE A RUNNING TOOL
UNATTENDED. Turn the power switch
to the “OFF” position.
DO NOT leave the tool until it has come
to a complete stop.
17. DO NOT STAND ON A TOOL. Serious
injury could result if the tool tips over,
or you accidentally contact the tool.
18. DO NOT store anything above or near
the tool where anyone might try to stand
on the tool to reach it.
19. MAINTAIN YOUR BALANCE. DO NOT
extend yourself over the tool. Wear oil
resistant rubber soled shoes. Keep oor
clear of debris, grease, and wax.
20. MAINTAIN TOOLS WITH CARE. Always
keep tools clean and in good working
order. Keep all blades and tool bits
sharp, dress grinding wheels and change
other abrasive accessories when worn.
21. EACH AND EVERY TIME, CHECK FOR
DAMAGED PARTS PRIOR TO USING
THE TOOL. Carefully check all guards
to see that they operate properly, are not
damaged, and perform their intended
functions. Check for alignment, binding
or breaking of moving parts. A guard or
other part that is damaged should be
immediately repaired or replaced.
22. DO NOT OPERATE TOOL WHILE
TIRED, OR UNDER THE INFLUENCE
OF DRUGS, MEDICATION
OR ALCOHOL.
GENERAL SAFETY
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RT-RPU2400
23. SECURE ALL WORK. Use clamps or
jigs to secure the work piece. This is
safer than attempting to hold the work
piece with your hands.
24. STAY ALERT, WATCH WHAT YOU ARE
DOING, AND USE COMMON SENSE
WHEN OPERATING A POWER TOOL.
A moment of inattention while operating
power tools may result in serious
personal injury.
25. ALWAYS WEAR A DUST MASK TO
PREVENT INHALING DANGEROUS
DUST OR AIRBORNE PARTICLES,
including wood dust, crystalline silica
dust and asbestos dust. Direct particles
away from face and body. Always
operate tool in well ventilated area
and provide for proper dust removal.
Use dust collection system wherever
possible. Exposure to the dust may
cause serious and permanent respiratory
or other injury, including silicosis (a
serious lung disease), cancer, and death.
Avoid breathing the dust, and avoid
prolonged contact with dust. Allowing
dust to get into your mouth or eyes, or
lay on your skin may promote absorption
of harmful material. Always use properly
tting AS/NZS approved respiratory
protection appropriate for the dust
exposure, and wash exposed areas with
soap and water.
26. USE A PROPER EXTENSION CORD
IN GOOD CONDITION. Use of extension
cords should be avoided where possible.
When using an extension cord, be sure
to have a cord heavy enough to carry
the current your product will draw, and
with compatible pin conguration and
connections (NEVER use an extension
cord rated at less than your machine).
Longer run extensions will need heavier
duty extension cords. Only connect
your extension cord or machine to
a receptacle that accepts your plug
and never modify your plug to suit a
receptacle.
SAFETY INSTRUCTIONS
9

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SPECIFIC ROUTER SAFETY
!
Some dust created by power sanding,
sawing, grinding, drilling and other
construction activities contains
chemicals known to cause cancer, birth
defects or other reproductive harm.
SOME EXAMPLES OF THESE
CHEMICALS ARE:
• Lead from lead-based paint
• Crystalline silica from bricks and cement
and other masonry products, and Arsenic
and chromium from chemically-treated
lumber.
Your risk from these exposures varies,
depending on how often you do this type
of work. To reduce your exposure to
these chemicals: work in a well-ventilated
area, and work with approved safety
equipment, such as those dust masks
that are specically designed to lter out
microscopic particles.
• Disconnect the power supply before
making any adjustments or changing bits.
Inspect bits carefully before installing
• Read, understand, and follow the
instructions packaged with the router
table and router lift. Do not plug in
Remote Power until Router Table Motor is
fully installed.
• Always make sure the work piece is free
from nails, screws, and other foreign
objects.
• Never start the tool when the bit is in
contact with the material. The bit cutting
edge may grab the material causing loss
of control of the work piece.
• Never place hands near the moving cutter
• Never touch the bit during or immediately
after use. After use the bit may be hot
enough to burn bare skin.
• Never use dull or damaged bits and sharp
bits must be handled with care.
• Dull bits require more force, which
could cause the bit to break.
• Damaged bits can throw carbide
pieces and burn the work piece
• Wear safety glasses or goggles, or a face
shield (with safety glasses or goggles) and
appropriate hearing protection.
• Ensure that the bit is securely mounted
in the chuck and the Router Power Unit
is tightly clamped in the Router Lift
• Make sure that the bit can rotate freely
before reconnecting and switching
on the power.
• Keep all cords clear of cutting area.
• To reduce the risk of injury, avoid “climb
cutting.” Climb cutting can cause the
work piece to be thrown violently out
of your control. Even small router bits
can result in climb cutting. Always feed
the work piece against the cutter rotation.
10

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RT-RPU2400
Also, do not ‘back up’ the stock during
a cut. This can also result in unexpected
‘kickback’.
• After changing the bit or making any
adjustments, make sure the collet nut and
any other adjustment devices are securely
tightened. Loose adjustment devices
can unexpectedly shift, causing loss of
control. Loose rotating components will
be violently thrown. Watch for vibration
or wobbling that could indicate an
improperly installed bit.
• Use the cutter (and spindle speed / RPM)
suited for the job and bit installed.
• Remove all wrenches and tools used
in the set up from the table.
• Make sure all guards are in proper
position
• Use jig xtures, holders, and hold-down
push blocks. Fasten the work securely
in a jig. When a table guide pin is used,
make sure it is adjusted and will not slip.
• Use extra care in machining stock that
contains cross grains or knots. These may
pull the operator’s hands into the knives
or may cause kickbacks.
• Do not leave a shaper machine running.
Make sure that the power is shut o and
that the cutter head has stopped revolving
before leaving the area.
• Do not make deep cuts or feed the stock
too rapidly.
• Do not cut stock that has loose knots,
splits, defects or foreign objects (e.g.,
metal, stone) in it.
• Do not distract or startle an operator
during a shaping operation.
• Do not remove saw dust or cuttings
around knives by hand or with
compressed air. Use a stick or brush.
• Do not clear the table while the cutter
is rotating.
• Do not accumulate stock or nished
work on the table.
• Do not stand in line with the stock
being fed.
• Do not wear loose clothing, work gloves,
neckties, rings, bracelets or other
jewellery that can become entangled with
moving parts.
• Use only specically recommended
accessories. Others may be hazardous.
SAFETY
11

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ELECTRICAL SAFETY
!
This tool must be grounded while
in use to protect the operator from
electric shock.
IN THE EVENT OF A MALFUNCTION OR
BREAKDOWN, grounding provides the path
of least resistance for electric current and
reduces the risk of electric shock. This tool
may be equipped with an electric cord that
has an equipment grounding conductor and
a grounding plug. The plug MUST be plugged
into a matching electrical receptacle that is
properly installed and grounded in accordance
with ALL local codes and ordinances.
DO NOT MODIFY THE PLUG PROVIDED.
If it will not t the electrical receptacle,
have the proper electrical receptacle installed
by a qualied electrician.
IMPROPER ELECTRICAL CONNECTION
of the equipment grounding conductor can
result in risk of electric shock. The conductor
with the green insulation (with or without
yellow stripes) is the equipment grounding
conductor. DO NOT connect the equipment
grounding conductor to a live terminal if repair
or replacement of the electric cord or plug
is necessary.
CHECK with a qualied electrician
or service personnel if you do not
completely under- stand the grounding
instructions, or if you are not sure the
tool is properly grounded.
Use only a 3-wire extension cord
that has a 3-prong grounding plug
and a 3-pole receptacle that accepts
the tool’s plug. replace a damaged or
worn cord immediately.
Power tools and machinery are intended
for use on a circuit that has an electrical
receptacle as shown in FIGURE A. FIGURE
Ashows a 10 Amp 3-wire electrical plug and
corresponding electrical receptacle that has
a grounding conductor.
If this particular tool has been designed and
tted with a two prong electrical plug, ensure
it displays the ‘Double Insulated’ logo shown
in FIGURE B, before connecting to a 3-wire
receptacle.
!
Never modify the standard tted
electrical plugs to t your receptacle.
FIG A. FIG B.
12

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RT-RPU2400
OVERLOAD PROTECTION
Before the motor is overloaded, the electronic
overload protection circuit will turn o the tool.
SOFT START
The Soft-Start feature reduces the amount
of torque reaction of the tool. This feature
gradually increases the motor speed up from
zero to the speed set by the variable speed
dial.
FEEDBACK CONTROL
The electronic speed control system allows
the tool to maintain constant speed between
no-load and load conditions.
!
To reduce the risk of injury, always use
feather boards, push sticks or push
blocks with proper guarding. Keep hands
away from moving bit. Refer to the Router
Table manual for proper table setup and
use.
CUTTING
The speed and depth of cut will depend
largely on the type of material being used.
Keep the cutting pressure constant but do
not use excessive force so the motor speed
slows excessively. It may be necessary
on exceptionally hard woods or problem
materials to make more than one pass to get
the desired depth of cut.
Before beginning the cut on the actual work
piece, it is advisable to take a sample cut on
a scrap piece of lumber. This will show you
exactly how the cut will look as well as enable
you to check dimensions. Position the fence
so that the work piece feeds against the
cutter rotation.
ELECTRICAL SAFETY

!
To reduce the risk of injury, avoid “climb
cutting.” Climb cutting can cause the
work piece to be thrown violently out of
your control. Even small router bits can
cause in climb cutting.
13

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SPECIFICATIONSSPECIFICATIONS
VOLTS AC 230V~50Hz
HORSEPOWER 2400W (input) 1800W (output)
NO LOAD RPM 10,000 – 22,000
OVERVIEW
ROUTER MOTOR OVERVIEW
Fig. 2
A. Collet Chuck B. Speed Control C. ON/OFF Switch
14
A
B
C

CARBATEC.COM.AU
RT-RPU2400
!
To reduce the risk of injury, always
unplug tool before attaching or removing
accessories or making adjustments.
Use only specically recommended
accessories. Others may be hazardous.
COLLETS & NUTS
The collet must be attached to the collet nut
before it is put into the collet chuck. Be sure
that the size of the collet matches the size of
the bit shank being used. If the wrong size
bit shank is used, the collet may break. For
attaching or detaching the collet nut to the
collet, follow the illustrated instructions on
next pages.
ATTACHING COLLET
TO COLLET NUT:
Fig. 3
This product includes a ¼” and ½” collet,
as shown in Fig. 3
Each Collet & Nut threads onto the collet
chuck with a standard right hand thread.
Do not tighten the Collet & Nut without
a bit inserted to avoid damage.
ASSEMBLY
ASSEMBLY
FIG. 3
FIG. 4
15

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ASSEMBLY
INSTALLING THE ROUTER
MOTOR INTO A TABLE LIFT
Fig. 5-7
The Router Power Unit must be clamped into
an appropriate Router lift or other mounting
device before use.
!
Do not attempt to use the Router Power
Unit hand held
1. Wind Router lift to its minimum height.
(Fig. 5)
2. Loosen Router Clamp & insert Router
Power Unit into the lift till the housing
touches the bottom of the lift plate.
(Fig. 6)
3. Firmly clamp the Router Power Unit into
the lift and check for a tight t. (Fig. 7)
ASSEMBLY
FIG. 5
FIG. 6
FIG. 7
17

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ASSEMBLY
INSTALLING THE BIT
Fig. 8-10
If the Router Power Unit is mounted in a
Router Lift, it is not necessary to remove
the motor from the lift to install a collet
assembly or a bit
Disconnect Power and raise the motor as high
as possible. Always wipe wood chips, dust,
or other foreign materials from the collet shaft
and collet assembly before assembling.
INSERT THE COLLET ASSEMBLY
INTO THE COLLET SHAFT.
Insert the bit shank into the collet
as follows:
1. Insert the bit shank into the collet as far
as it will go (Fig. 8).
2. Back the bit shank out slightly to avoid
bottoming out. Be sure there is a
minimum of 1.5mm between the bottom
of the collet assembly and the radius to
the cutting portion of the bit (Fig. 9)
3. To tighten the bit in the collet assembly
use two wrenches in the direction shown.
(Fig. 10).
Never tighten a collet assembly without
inserting a bit shank of the proper size.
This may damage the collet.
FIG. 8
FIG. 9
FIG. 10
1.5mm
TIGHTEN
18

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REMOVING THE BIT
Fig. 11-12
1. Loosen the collet nut from the collet
shaft using two wrenches in the direction
shown (Fig. 8).
2. Once loose, unscrew the collet nut
by hand until it feels tight again.
3. Return to using the wrenches until the
bit shank can be pulled out (Fig. 12).
FIG. 12
FIG. 11
LOOSEN
ASSEMBLY
19

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OPERATION
SPEED
SETTING RPM MAX. BIT DIAMETER
Slow 10,000
- 12,000 3” to 3-½”
Medium 14,000
- 16,000 2-¼” to 2-½”
Medium 18,000 1-¼” to 2”
Fast 20,000 1”
Fast 22,000 <1”
VARIABLE SPEED DIAL
Fig. 13
The variable speed dial allows you to adjust
the rotating speed Revolutions Per Minute
(RPM) of the tool.
Use the following chart to determine the best
speed for the bit diameter.
FIG. 13
20