Rotabroach SMARTPUMA1 User manual

Issue 2 Original version Sept 2010
Ratahtioack
PUMA MAGNETIC DRILLING MACHINE
FEATURING
Model No. SMARTPUMA1 &
SMARTPUMA3
This machine (Serial No ) is CE approved.
Rotabroach Ltd
Imperial Works, Sheffield Road
Sheffield, South Yorkshire
United Kingdom
S9 2YL
Tel: [phone] Fax: [phone]
Email: sales @ rotabroach.co.uk Web site: www.rotabroach.co.uk
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Issue 2 Original version Sept 2010
Other products by Rotabroach.
A
r
L
L
GETIC
Natal' /tench MADRILLS
Designed in the UK a vast range- of machines are
available from Rotabroach. Ensuring we have a
machine to match any application.
Our range of machines includes
Small machines Viper and Puma
Medium machines Panther and Hawk
Large machines Cobra and Scorpion.
Specialist machines Pneumatic and
Hydraulic.
Rail drilling machines The Rhino's"
-99
RataiLltorzeit CUTTER
Produced to a specific geometry our cutter and
drills are design to give you the maximum
performance every timel
productsA range of pruoucts are available from
M2 tool steel cutters
M42 tool steel cutters
Tungsten carbide tipped cutters
Twist drills with Weldon shank
Titanium Nitride coated cutters
Specialist railway Tungsten carbide
tipped cutters
Solid indexable insert cutters.
Mini cutters designed for use in a
standard F inch (13mm). drill chuck.
For more information please visit our website at www.rotabroach.co.uk
Or contact our sales department on [phone]
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Issue 2 Original version Sept 2010
Contents
Page
1) Intended Use 3
2) General Safety 3
3) Machine Specification 5
4) Operating Instructions and Additional Safety 6
5) Cutsmart Feature 7
6) Mounting of cutters 8
7) Remedies for hole making problems 8
8) Wiring Diagram 9
9) Exploded diagram of machine 10
10) Exploded diagram of motor 12
11) Pipe adaptor Kit 14
12) Chuck conversion 15
13) Maintenance checks 15
14) Trouble shooting 17
15) Cutter Selection, Speeds and Feeds 18
16) Warranty 20
1) INTENDED USE
The magnetic drill is intended for use to drill a hole in a ferrous material. The magnet is used to hold the drill in
place whilst the drill is functioning elevating the stress placed on the user and increase the low precision that
would be incurred when using a hand held drill. It is designed for use in Fabrication, Construction, Railways,
Petrochemical and any other application when drilling ferrous metal. Any deviation from its intended use will
not be the subject of responsibility from Rotabroach.
2) GENERAL SAFETY RULES
WARN INC,! When using electric tools basic safety precautions should always be followed to reduce the risk of fire, electric shock and
personal injury, including the following.
Read all these instructions before attempting to operate this product
Remove the power supply before carrying out any adjustment, serving or maintenance.
1. Keep work area clear cluttered areas and benches invite injuries.
2. Consider work area environment
Do not expose tools to rain.
Do not use tools in damp or wet locations.
Keep work area well lit.
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Issue 2 Original version Sept 2010
Do not use tools in the presence of flammable liquid or gases.
3. Guard against electric shock
Avoid body contact with earthed or ground surfaces (e.g. pipes, radiators, cookers and refrigerators). Electric safety can be further
improved by using a high-sensitivity (30 m A/0.1s) residual current device (RCD).
4. Keep other persons away do not let persons, especially children, not involved in the work touch the tool or the extension cord and keep
them away from the work area.
5. Store idle tools when not in use, tools should be stored in a dry locked-up place, out of reach of children.
6. Do not force the tool it will do the job better and safer at the rate for which it was intended.
7. Use the right tool
Do not force small tools to do the job of a heavy duty tool.
Do not use tools for purposes not intended: for example do not use circular saws to cut tree limbs or logs.
8. Dress properly
Do not wear loose clothing or jewellery; they can be caught in moving parts.
Non-skid footwear is recommended when working outdoors.
Wear protective hair covering to containing long hair.
9. Use protective equipment when using this machine
Use safety glasses.
Use ear defenders.
Use face or dust mask if cutting operations create dust.
Use protective gloves
10. Connect dust extraction equipment if device are provided for the connection of dust extraction and collecting equipment, ensure these
are connected and properly used.
11. Does not abuse the cord; never pull the cord to disconnect it from socket. Keep the cord away from heat, oil and sharp edges.
12. Secure work where possible use clamps or a vice to hold the work. It is safer than using your hand.
12. Do not overreach keep proper footing and balance at all times.
13. Maintain tools with care
Keep cutting tools sharp and clean for better and safer performance.
Follow instruction for lubricating and changing accessories.
Inspect tool cords periodically and if damaged have them repaired by an authorized service facility.
Inspect extension cords periodically and replace if damaged.
Keep handles dry, clean and free oil and grease.
15. Disconnect tools when not in use, before servicing and when changing accessories such as blades, bits and cutters, disconnect tools
from the power supply.
16. Remove adjusting keys and wrenches form the habit of checking to see that keys and adjusting wrenches are removed from the tool
before turning it on.
17. Avoid unintentional starting ensure switch is in "off" position when plugging in.
18. Use outdoor extension leads when the tool is used outdoors; use only extension cords intended for outdoor use and so marked.
19. Stay alert watch what you are doing, use common sense and do not operate the tool when you are tired.
20. Check for damaged parts before further use of tool; it should be carefully checked to determine that it will operate property and its
intended function.
21. Warning! The use of any accessory or attachment other than one recommended in this instruction manual may present a risk of
personal injury.
22. Have your toll repaired by a qualified person
This electric tool complies with the relevant safety rules. Qualified persons using original spare parts should only carry out repairs;
otherwise this may result in considerable danger to the user.
Foreseeable Misuse
During operation, failure to keep the cable away from the machine body, will result in the cable damaged by drill bit, causing electric
conduction and other accidental injury.
Before operation, when plugging the power source, failure to turn all the switches to position <off>, may result in accidental start-up
from the machine, causing accidental injury.
During suspended operation, failure to tie the safety belt to fasten the magnetic drill, when power failure or power down suddenly,
causing magnetic drill to get out of the work surface and resulting in the accident.
Other risks
During operation, wear loose clothing or jewellery, failure to wear protective hair covering to containing long hair, they can be caught
in moving parts, may present an accidental injury.
During operation, put in effort to push and press the machine, will result the magnet getting out of the work surface suddenly,
causing accidental injury.
Before mounting or removing the drill bit, failure to disconnect the supply, will result the accidental start-up, causing personal injury.
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Issue 2
3) Specification
Original version
Maximum hole cutting capacity in .2/.3C steel = 30mm dia. x 25mm deep
Arbor bore = 19.05mm (3/4") dia.
Sept 2010
Model Voltage (V)(AC) Normal Full Load
Watts (W)
SMARTPUMA1 110V 50-60Hz 800
SMARTPUMA3 230V 50-60Hz 800
Electro Magnet Model Voltage (V)(DC) Normal Full Load
Amps (A) Watts (W)
SMARTPUMA1 110 0.45 45
SMARTPUMA3 230 0.225 45
Total Normal Full Load (magnet + motor) 845
Overall
Dimensions Height (maximum extended) 410mm
Height (minimum) 360mm
Width (including Hand wheel) 170mm
Length Overall (including Guard) 250mm
Magnet Footprint 165mm x 80mm
Net Weight 11.20kgs
Stroke With Arbor
With Drill chuck 30mm max 65mm
No Load
Speed All voltages 600rpm
Tractive Force of Magnet at 20° C (25mm min. plate thickness)
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.
8000N
Maximum hand/arm vibration magnitude (measured at handle during operation in
accordance with IS05349 using a 22mm dia. cutter through 13mm mild steel plate. 2.95 m/s2
Estimate of vibration exposure. Operation 30 holes @ 1 minute/hole. 0.39 m/s2 A(8)
Average noise level during cutting at operators ear position. LPA Max. 88.3 dB(A)
LwA Max. 101.3dB(A)
Suitable only for a single phase 50-60 Hz 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
List of Contents with Magnetic Dill Unit Check
List
RD4329 Safety Strap YES/NO
RD4088 4mm A/F Tee Handled Hexagon Key YES/NO
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Issue 2 Original version Sept 2010
4) Operating Instructions and Additional Safety
! READ SAFETY INSTRUCTIONS BELOW BEFORE USING THE MACHINE !
When using electrical tools, basic safety precautions should always be followed to reduce the risk of electric shock, fire, and personal
injury.
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 or gasses. Failure to do so may result in personal injury.
BEFORE operating, the machine MUST be securely restrained to a fixed independent feature (by using safety strap RD4329, 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 eye and ear protectors 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.
Before operating, ALWAYS ensure cutter retaining screws are secured.
Regularly clear the work area and machine of swarf and dirt, paying particular attention to the underside of the magnet base.
With a gloved hand, and after switching off, remove any swarf that might have gathered around the cutter and arbor before proceeding
with cutting.
ALWAYS remove tie, ring, watches and any loose adornments that might entangle with the rotating machinery before operating.
Should the cutter become 'fast' in the work-piece, stop the motor immediately to prevent personal injury. Disconnect from power
source and turn arbor to and fro. DO NOT ATTEMPT TO FREE THE CUTTER BY SWITCHING THE MOTOR ON AND OFF.
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 that nuts and screws are tight.
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 eject. DO NOT operate the machine if the ejected slug may cause injury.
When not in use ALLWAYS store the machine in a safe and secure location when not in use.
ALLWAYS ensure that approved ROTABROACHTm agents conduct repairs.
OPERATION
Keep the inside of the cutter clear of swarf. It restricts the operating depth of the cutter.
Apply the cutting fluid to the reservoir via the inducement slots in the arbor. It is then "metered out" by the pilot and is applied
directly to the cutting edge. Alternatively, fluid can be applied directly on to the work-piece making certain that it floods into the
groove formed by the cutter.
Occasionally depress the pilot to ensure cutting fluid is being correctly metered.
To start the machine, first switch on the magnet by turning the rotary switch to position <1>. Then start the motor by depressing the
GREEN start button.
ALWAYS switch off the motor by depressing the RED stop button. DO NOT switch off the motor by turning the magnet switch to
zero.
Apply light pressure when commencing to cut 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 when using the Rotabroach "Puma" machine. 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). Continuous overloading will result in damage to the machine and cutter.
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 tomake
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 slide and arbor support bearing.
Insecure anchorage, a loosely fitting slide, or a worn bearing in the arbor support bracket usually causes cutter breakage. (Refer to
routine maintenance instructions).
EXTENSION CABLE SELECTION
The machines are factory fitted with a 3 metre length of cable having three, 1.5mm2 conductors, 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.
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: 26 metres of 3 core x 1.5mm2 or 17metres of 3 core x 1.0mm2
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Issue 2
5) Cutsmart feature
Original version Sept 2010
Ratak/teach
FEATURING
'Cut Smart' is a new feature from Rotabroach.
Designed to help you to get the best out of your machine. It does this by way of a visual indicator.
The visual indicator shows when you are using the drill correctly within its specification this is done by way of a
Tri colour LED to the Right of the magnet on LED.
During operation if you are drilling correctly this will stay GREEN. However as you put more pressure onto the
drill increasing its workload above its correct operation the LED will start to change colour to ORANGE. This
indicates that you are putting more wear on the machine and the cutter which will eventually cause damage to
your machine. If further pressure is put on the machine the LED will eventually turn RED and the motor will cut
off and will not be allowed to be turned back on for approximately 5 seconds. This is a safety feature to protect
you and the machine from damage.
Ideally to get the most out of your machine you need to keep the LED green when drilling If it starts to turn
orange release some pressure.
The panels are set to cut off when the machine reaches the following currents.
110V panel - approximately 17 amps
230V panel - approximately 10 amps
The magnet is also protected by a 2A fuse
Care must be taken when handling the PCB as they are static sensitive please ensure you are earthed. As the
PCB contains some delicate components please do not flash test this equipment.
New Cutsmart
indicator
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7
Indicator turns
orange when too
much pressure is
added on the
cutter. Will turn
Red and cut
power to motor if
machine is given
too much force
for the motor to
cope with.
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Issue 2 Original version Sept 2010
6) MOUNTING OF CUTTERS
(See exploded view of complete machine)
The machine has been made to accept cutters having 19.05mm (3/4") dia. 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 #12.5.
Take appropriate pilot and place through hole in shank of cutter. Insert shank of cutter into 1/4" dia. bore of arbor, ensuring
alignment of two drive flats with socket screws #12.5.
Tighten both screws using hexagon key RD4088.
ALWAYS DISCONNECT MACHINE FROM POWER SOURCE.
7) REMEDIES FOR HOLE MAKING PROBLEMS
Problem Cause Remedy
1) Magnetic base
won't hold
effectively
Material being cut may be too thin for efficient
holding.
Swarf or dirt under magnet.
Irregularity on magnet contact or work-piece.
Insufficient current going to magnet during drilling
cycles.
Attach an additional piece of metal under work-piece where
magnet will be located, or mechanically clamp magnetic base to
work-piece.
Clean magnet.
Use extreme care; file any imperfections flush to surface.
Confirm power supply and output from control unit, check
supply cable.
2) Cutter skips
out of centre-
punch mark at
initiation of cut
Magnetic base is not holding effectively.
Worn arbor bushing and/or ejector collar.
Too much feed pressure at start of cut.
Cutter is dull, worn, chipped or incorrectly sharpened.
Poor centre-punch mark; weak pilot spring; pilot not
centred in centre-punch mark.
Worn or bent pilot, worn pilot hole.
Loose bolts on motor bushing support bracket, main
casting or loose gib adjusting set screws.
See causes and remedies above.
Replace! Only a few thousandths wear permissible. New arbor
bushing is needed.
Light pressure only is needed until a groove is cut. The groove
then serves as a stabilizer.
Replace or re-sharpen. Sharpening service is available.
Improve centre-punch and/or replace worn parts
Replace part or parts
Adjust where necessary
3) Excessive
drilling pressure
required
Incorrectly re-sharpened, worn or chipped cutter.
Coming down on swarf lying on surface of work-
piece.
Gibs out of adjustment or lack of lubrication.
Swarf accumulated (packed) inside cutter.
Re-sharpen or replace.
Take care not to start a cut on swarf.
Adjust setscrews, and lubricate.
Clear cutter.
4) Excessive
cutter breakage Steel swarf or dirt under cutter.
Incorrectly re-sharpened or worn cutter.
Cutter skipping.
Slide-ways need adjustment.
Cutter not attached tightly to arbor.
Insufficient use of cutting oil or unsuitable type of
oil.
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.
See causes and remedies (2).
Tighten sideway.
Retighten.
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 See cause and remedy above
Incorrectly re-sharpened cutter.
Insufficient or spasmodic cutting pressure.
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.
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Issue 2
8) WIRING DIAGRAM
Original version Sept 2010
TERMINAL
BLOCK
12
MOTOR
3
CO
45
0
MAGNET
REED
SWITCH
7 8 9
444
MAGNET
N
MAINS CABLE
230V WIRING DIAGRAM
444
TERMINAL
BLOCK
12
MOTOR
3
U
CO
4 5 6
MAGNET
REED
SWITCH
789
444
MAGNET
N
MAINS CABLE
11DV WIRING DIAGRAM
444
No Function Wire Colour
1Magnet 1- (110v & 230v Magnet) Black
2Magnet 2+ (110v & 230v Magnet) Red
3Motor Blue
4Magnet reed switch Black
5Motor Brown
6N/C
7Mains (Neutral) Blue
8Magnet reed switch Red
9Mains (Live) Brown
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Issue 2 Original version Sept 2010
9) Exploded view of Puma
11.
29
28
014(12.4
111
2.3
2.2 co
0.4
10.3
10.1
10.2-vo%
9.2
9.1
10.4
10
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Issue 2 Original version Sept 2010
Com onent parts list for Rotabroach Puma CM/300/1 & CM/300/3 From serial number 107621
Item Part number Discription Quantity Item Part number Discription Quantity
1RD23094 Control panel assembly 110v. 18.6 RD43093 Screw. 1
1RD23095 Control panel assembly 230v. 18.7 RD43116 Spacer block 1
2RD23081 Magnet assembly 110v. 19RD23014 Bearing bracket assembly. 1
2RD23083 Magnet assembly 230v. 19.1 RD33099 Bearing bracket. 1
2.1 RD45606 Protection Switch 19.2 RD4518 Bearing a1
3RD23008 Capstan assembly. 110 RD23015 Arbor sleeve assembly. 1
3.1 RD33088 Capstan spindle. 19RD23014 Bearing bracket assembly. 1
3.2 RD43091 Capstan ball. 310.1 RD33100 Ejector sleeve. 1
3.3 RD33089 Capstan arm. 310.2 RA353 Pin. 1
3.4 RD33090 Capstan pinion sleeve. 110.3 RD4519 Thrust washer. 2
3.5 RD33092 Bearing. 210.4 RD43084 Circlip. 2
3.6 RD4098 M6 Socket head cap screw. 111 RD23016 Guard assembly. 1
3.7 RD4207 M6 Spring washer. 111.1 RD33101 Guard. 1
4RD23064 Motor & Gearbox assy 110v. 111.2 RD33102 Guard bracket 1
4RD23065 Motor & Gearbox assy 230v. 111.3 RD43092 Screw. 2
5RD23009 Mains cable assembly 110v. 111.4 RD43096 Screw. 2
5RD23012 Mains cable assembly 230v. 111.5 RD43097 Ball plunger 2
6RD23003 Housing assembly. 111.6 RD43098 Shakeproof washer. 1
6.1 RD33094 Housing. 111.7 RD4252 M3 screw 1
6.2 RD4102 Tension pin. 212 RD23019 Arbor assembly. 1
6.3 RD33077 Logo plate. 112.1 RD33137 Arbor spindle. 1
6.4 RD4077 Screw. 412.2 RD4056 Circlip. 1
6.5 RD43093 Screw. 112.3 RA354 Button. 1
6.6 RD4069 Shakeproof washer. 112.4 RD3319 Spring. 1
6.7 RD4068 Nut. 212.5 RD4066 M8 Socket screw. 4
6.8 RD43094 Earth tag. 113 RD23018 Gib strip assembly 1
6.9 RD4070 Washer. 113.1 RD33103 Fixed gib strip 1
6.10 RD4312 Screw. 413.2 RD33104 Adjustable gib strip 1
6.11 RD4302 Information plate. 113.3 RD33105 Gib support strip 1
6.13 RD4077 M4 x 8 Pan head 114 RD33106 Motor support bracket. 1
6.14 RD43113 M4 spring washer 115 RD4157 M6 Socket head screw. 2
6.15 RD43117 Mains cable clamp 116 RD4096 M6 Shakeproof washer. 2
6.16 RD33145 Depth Guage 117 RD4091 M5 Socket head screw. 4
6.17 RD33146 Rivet 118 RD4092 M5 Shakeproof washer. 4
6.18 RD33144 Rubber Handle 119 RD33107 Bearing spacer. 1
6.19 RD43093 Screw 220 RD4319 M8 Bolt 2
7RD23010 Motor supply cable assembly. 121 RD4079 M8 Shakeproof washer 2
7.1 RD33095 Cable assembly. 222 RD4078 M8 Washer 2
7.2 RD43095 cable clip. 223 RD4098 M6 Socket head cap screw. 2
7.3 RD43020 Motor cable elbow 124 RD4095 M6 Washer. 2
7.4 RD43112 Connector 125 RD4329 Safety Strap 1
8RD23004 Slide assembly 126 RD4088 4mm Allen Key 1
8.1 RD33096 Slide. 127 RD43099 13mm Drill Chuck 1
8.2 RD33097 Rack. 128 RD33153 Drill Chuck Adaptor 1
8.3 RD4325 M5 socket head screw. 229 RD33154 Drill Chuck Key 1
8.4 RD4092 M5 Shakeproof washer. 2
8.5 RD4069 Shakeproof washer. 1
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Issue 2 Original version Sept 2010
10) EXPLODED VIEW-MOTOR AND GEARBOX (From
serial No 106991 and greater)
8
6.7
6.3
5.3
5.2
5.4
5.1
5.2
10
12
4.2
3.5
3.4
1.3
lar
C:11
ka
3.3
1111111111111111111111111
110
4.1
4.4
3.6
4.4
2.1
3.1
2.2
1.1
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Issue 2 Original version Sept 2010
COMPONENT PARTS - MOTOR AND GEARBOX (Serial No
106991 and greater)
Item Part
Number Description Qty Item Part Number Description Qty
1RD23020 Output shaft assembly. 16.2 RD33111 Field coil 110v. 1
1.1" RD33139 Output shaft. 16.3 RD33085/B Motor casing. 1
1.2 RM304210 Bearing. 16.4 RD33086 Brush end cap. 1
1.3 RM33876 Circlip. 16.5 RM297640 Carbon Brush assy 110v. 2
2RD23024/B Gearbox Housing assembly. 16.6 RD43089 Screw. 2
2.1 RD33081/B Gearbox Housing. 16.7 RD43118 Capacitor 1
2.2 RD43084 Circlip. 16.8 RD43119 Terminal 1
3RD23001/B Gearbox assembly. 16.9 RD43120 Screw. 4
1RD23020 Output shaft assembly. 16.10 RD43121 Brush cover spring 1
2RD23006/B Gearbox Housing assembly. 16RD23023/B Motor case assembly 230v 1
3.1 RD43085 Screw. 46.1 RD33084 Field coil baffle. 1
3.3" RD33128 Key 16.2 RD33113 Field coil 230v. 1
3.4 RD33082 Final drive gear. 16.3 RD33085/B Motor casing. 1
3.5 RD43087 Circlip 16.4 RD33086 Brush end cap. 2
3.6 RD33083 Intermediate gear. 16.5 RM297630 Carbon Brush assy 230v. 2
4RD23007/B Inner Gearplate assembly. 16.6 RD43089 Screw. 2
4.1 RD33108 Inner Gearplate. 16.7 RD43118 Capacitor 1
4.2 RD43088 Ph Bz Bearing. 16.8 RD43119 Terminal 1
4.4 RM22880 Needle Bearing. 26.9 RD43120 Screw. 4
5RD23011 Armature assembly 110v 16.10 RD43121 Brush cover spring 2
5.1 RD33091 Armature 110v 17RD23031 Motor assembly 110v 1
5.2 RM17134 Bearing. 2 5 RD23011 Armature assembly 110v 1
5.3 RD43122 Washer 3 6 RD23021/B Motor case assembly 110v 1
5.4 RD43123 Dust proof Ring 19RD33087/B Motor end cap 1
5RD23013 Armature assembly 230v 18RD43090 Screw. 2
5.1 RD33093 Armature 230v 17RD23033 Motor assembly 230v 1
5.2 RM17134 Bearing. 25RD23013 Armature assembly 230v 1
5.3 RD43122 Washer 3 6 RD33113 Field coil 230v. 1
5.4 RD43123 Dust proof ring 18RD43090 Screw. 2
6RD23021/B Motor case assembly 110v 19RD33087 Motor End Cap 1
6.1 RD33084 Field coil baffle. 110 RD43020 Motor Cable elbow 1
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Issue 2 Original version Sept 2010
11) 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 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.
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Issue 2 Original version Sept 2010
12) CHUCK CONVERSION.
To remove the arbour lay the machine on its side.
Unscrew the two grub screws at the top of the arbor
Some early machines will only have spanner flats on the arbor.
When the arbor has become detached from the spindle this can then be removed
Remove the arbour support bracket and guard with the arbour retained.
Mount the chuck using the chuck adaptor RD33153.
Replacing the chuck is the reverse sequence.
13) Tips for keeping your machine in correct working order.
In order to 'get the best life' out of your Rotabroach machine always keep in good
working order. A well maintained machine is a happy machine.
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 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
Visually check the machine for damage.
Machine must be checked before operation for any signs of damage that will affect the operation
of the machine. Particular notice must be taken of 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.
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Issue 2 Original version Sept 2010
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 the
original length the brushes should be changed. Failure to do so may cause damage to the
machine.
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 centre 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 supply and switch on 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 the machine.
Check Armature of the machine.
This should be checked at least 1 per month to check that there are 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 this is normal as this is the part that comes in contact with the brushes but any signs of
abnormal damage and the part should be replaced.
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Issue 2
14) TROUBLE SHOOTING
Original version Sept 2010
Magnet and motor do not function - 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
Magnet does function, the motor does not - 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
Magnet does not function, the motor does - Defective magnet
- Defective Fuse
- Defective Control Unit
Hole cutters break quickly, holes are bigger
than the hole cutter - Play in the guide - Bent spindle
- Shaft extending from the motor is bent
- Pilot bent
Motor running roughly and/or seizing up - Bent spindle
- Shaft extending from the motor is bent
- Triangular guide not mounted straight
- Dirt between spindle and triangular guide
Motor making a rattling sound - Gear ring (bottom of the armature) worn out
- Gear(s) worn out
- No grease in gear box
Motor humming, big sparks and motor has no
force - Armature damaged - Field burned
- Carbon brushes worn out
Motor does not start or fails. - Damaged or defective wiring
- Damage to Armature or field coil
- Damaged or defective brushes
Guiding takes a great deal of effort - Guide is set too tight
- Guide is dry
- Guide/gear- rack/rotation system dirty or damaged
Insufficient magnetic force - 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
Frame under voltage - Damaged / defective wiring
- Defective magnet
- Motor seriously dirty
Fuse blows when magnet switch is turned on - Damaged or defective wiring
- Wrong value fuse
- Defective magnet switch
- Defective Control Unit
- Defective magnet
Fuse blows when motor is started up - Damaged or defective wiring
- Wrong value fuse
- Motor running roughly
- Defective Armature and / or Field
- Carbon brushes worn out
- Defective Control Unit
Rotation system free stroke too long - Loose or defective gear-rack
- Defective rotation system
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Issue 2 Original version Sept 2010
15) Cutter selection, Speeds and Feeds
Material Material hardness Cutter
Mild and Free cutting steels <700N/min2 SRC or SRCL
Mild and Free cutting steels <850N/mm2 SRCV or SRCVL
Steel angle and joists <700N/mm2 SRC or SRCL
Steel angle and joists <850N/mm2 SRCV or SRCVL
Plate and sheet steel <700N/mm2 SRC or SRCL
Plate and sheet steel <850N/mm2 SRCV or SRCVL
Aluminium <700N/mm2 SRC or SRCL
Aluminium <850N/mm2 SRCV or SRCVL
Brass <700N/mm2 SRC or SRCL
Brass <850N/mm2 SRCV or SRCVL
Cast iron <700N/mm2 SRC or SRCL
Cast iron <850N /mm2 SRCV or SRCVL
Stainless Steel <700N/mm2 SRC or SRCL
Stainless Steel <850N/mm2 SRCV or SRCVL
Stainless Steel >850N/mm2 CWC, CWCL or CWCX
or SCRWC
Rail track >850N/mm2 CWC, CWCL or CWCX
or SCRWC
Tool Steel >850N /mm2 CWC, CWCL or CWCX
or SCRWC
Die steel >850N/mm2 CWC, CWCL or CWCX
or SCRWC
The data listed below is for reference purposes only, and indicate potential starting
conditions. It is the responsibility of the site operation manager to determine correct
application requirements.
xi.sorAcorairat. Cutting
surface
speed
Metershnin
Cutter diameteriMaterialiRPM relationship
13 14 18 22 30 50 65
Material to he
cut Lower -
Upper LUL ULULULULULU
Aluminium 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:
c ast(soft) 30 - 50 734 1224 682 1137 530 884 434 723 318 530 191 318 147 245
cast(hard) 15 - 21 367 514 341 477 265 371 217 304 159 223 95 134 73 103
cast(malleable) 15- 30 367 734 341 682 265 530 217 434 159 318 95 191 73 147
Steel: mild 24- 30 588 734 546 682 424 530 347 434 255 318 153 191 118 147
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) -.to i3 26 318 136 296 106 230 87 188 64 138 38 83 29 64
These are only starting points. They will vary with application and work piece condition.
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 matarials will require reduced feed rates.
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Original version Sept 2010
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Issue 2 Original version Sept 2010
Ratalutoack
WARRANTY STATEMENT
Rotabroach® warrants its machines to be free from faulty materials, or workmanship under normal use for a period of 6 months from
initial date of purchase and 90 days for all other parts (excluding cutters), provided that the warranty registration card (or online
registration) has been completed and returned to Rotabroach®, 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 Rotabroach® 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 in accordance with the operators 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 Rotabroach® 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 on www.rotabroach.co.uk
The warranty claim must be lodged 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 Rotabroach®, in no event shall Rotabroach® 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 MECHANTABLITY OR FITNESS FOR A PARTICULAR PURPOSE. ROTABROACH® RESERVE THE RIGHT TO MAKE
IMPROVEMENTS AND MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE
Known and Trusted Worldwide for Quality, Performance and Reliability
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