Rothenberger ROPOWER 50 R User manual

5.6050 230V
5.6045 110V
ROTHENBERGER Werkzeuge GmbH
Industriestraße 7 - D-65779 Kelkheim/Germany
Tel. [phone] / 800-1 - Fax [phone] / 7 44 22
E-Mail: [e-mail]
Internet: www.rothenberger.com
ROPOWER 50 R

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Imprint:
Instruction Manual ROPOWER 50 R
Instruction Manual No. 9.0252
© ROTHENBERGER Werkzeuge GmbH, 2004
We reserve the right to revise technical product specifications at any time without notice
Editorial : ROTHENBERGER Werkzeuge GmbH • D-65779 Kelkheim
Edition : 03 / 2004
Printed in the F.R. Germany
Please read the Instruction Manual carefully first! • Don't throw it away!
If damages are caused by operating errors or misuse the warranty expires!

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Contents Page
1. Safety notes 28
1.1 Correct use 28
1.2 Safety symbols used and their meanings 28
1.3 Notes on safety for persons and the machine 28
2. Technical data 30
3 Functions of the thread-tapping machine 31
3.1 Overview / accessories / description 31
3.1.1 Overview, thread-tapping machine 31
3.1.2 Overview, automatic thread-tapping head 31
3.1.3 Accessories 31
3.1.4 Functional description 32
4 Preparations for operation 32
4.1 Scope of delivery 32
4.2 Transporting the thread-tapping machine 32
4.3 Setting up the machine 33
4.4 Electrical connection 33
4.5 The thread-tapping oil 34
4.6 Checking the thread-tapping oil 35
4.7 Setting the supplied thread-tapping oil quantity 35
4.8 Draining off the oil 36
5 Operation of the thread-tapping machine 36
5.1 Clamping the workpieces 36
5.2 Cutting the workpiece with the pipe cutter (1) 37
5.3 Reaming the workpieces 38
5.4 Changing the thread size 39
5.5 Removing and installing the thread jaws from and in the thread-tapping head 39
5.6 Changing the thread size 41
5.7 Tapping threads 41
5.8 Setting the thread length 43
5.9 Setting the thread depth 43
5.10 Cleaning after use 44
6 Maintenance and inspection 44
6.1 Changing the internal deburrer blade 44
6.2 Changing the pipe cutter cutting wheel 45
6.3 Changing the clamping jaw inserts 46
6.4 Daily inspection 47
7 Troubleshooting 48
8 Disposal 48
8.1 Metal, electrical and electronic parts 48
8.2 Oils and lubricants 48
8.3 Waste from maintenance work 48
9 Warranty 49
10 Customer service 49

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1. Safety notes
1.1 Correct use
The thread-tapping machine ROPOWER 50 R may only be used for cutting off, making and deburring BSPT, NPT
threads measuring ¼” … 2” as described in Chapter 2 “Technical data”.
The ROPOWER 50 R thread-tapping machine may only be operated with suitable automatic tapping heads that
have been inspected and recommended by ROTHENBERGER Werkzeuge GmbH, and with thread-tapping jaws as
described in Chapter 2 “Technical data”.
Correct use of accessories:
Use the accessories available from the main catalogue only as described in the catalogue and as stated in the
operating instructions.
The supplied safety pedal carries the GS approval of the professional liability insurers’ association and is compulsory
for using the machine in the Federal Republic of Germany.
Never make technical or design modifications to the thread-tapping machine and to the accessory
parts. This would render the operating permit void and would represent an accident and injury risk.
When using electrical tools and machines, basic safety measures must be observed and followed in
order to provide protection against electric shock, injury and fire risks. Read the instructions
precisely before using the machine. Always keep the safety instructions to hand.
1.2 Safety symbols used and their meanings
Hazard to life and health, if the safety instructions are not followed.
If the safety instructions are not followed, there is a possibly hazardous situation that
can result in injury or material damage.
This symbol indicates important information for correctly handling the machine.
Ignoring these instructions can result in problems on the machine or the surrounding
area.
1.3 Notes on safety for persons and the machine
Never put fingers, your face, hair or other parts of the body, or loose, wide items of
clothing into the operating and intake areas of rotating parts (workpiece, clamping
chuck, centring chuck). Do not wear jewellery (rings, chains etc.). Risk of injury and
accidents!
Only use machines that operate faultlessly. If the machine is so heavily damaged (cracks,
deformation etc.) that electrical or drive parts are exposed, pull out the mains plug
immediately and contact Customer Service.
Maintenance and repair work may only be carried out by specialist workshops
authorised by Rothenberger. Incorrect repairs can present significant hazards for the
user!

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In the event of faults (unusual smell, vibrations, unusual noises) during work with the
ROPOWER 50 R, it is essential to immediately press the safety pedal and perform an
EMERGENCY STOP of the machine!
If the machine is running, it is prohibited to hold the workpieces manually or to perform
similar work, and to fit and remove parts such as filters, valves, pipe sections etc!
Only persons who have been instructed on how to operate the machine may carry out
work listed in Chapter 1.1 “Correct use”!
Never operate the machine when tired or when under the influence of alcohol, medicines
or drugs!
Wear safety clothing!
Wear a safety mask to provide protection against splashes of thread-tapping oil as well
as any chlorine gas vapours (from thread-tapping oil burning on hot tool and workpiece
surfaces)!
Wear a safety hat to cover and protect long hair.
Wear safety gloves when changing the thread-tapping jaws, the pipe cutting wheel and
the pipe deburrer.
Wear safety gloves when changing the tool and workpiece. The thread and thread
cutting jaws get hot during thread-tapping!
Wear safety footwear. Risk of injury (slipping) on any escaping thread-tapping oil! Risk
of injury from wet, slippery and possibly off-centre machine parts when changing the
tool!
Do not remove metal and plastic chips using compressed air! There is a risk of eye
injuries and loss of eyesight!
Keep the working area clean and orderly. Disorder at the workplace increases the risk of
accidents and injuries!
Remove hand tools from the machine before switching it on! Risk of accidents and
injury!
Take account of ambient influences! Ensure that the lighting is good! Do not leave
electrical tools out in the rain! Do not use electrical tools in a damp or wet environment!
Risk of electric shock!
Do not use electrical tools near flammable liquids or gases. Risk of detonation and
explosion!
Ensure sufficient ventilation during indoor use (closed rooms).
The permissible ambient temperature is between 0°C and 40°C!
Keep tools in a safe place! When they are not being used, store tools in a dry, locked
room so that they are not accessible to children!

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Do not allow any persons who are not employed by the company or uninstructed
persons to operate / touch the machine and tools or the mains power cable!
If the machine is not to be used for some time, it is essential to switch it off and to pull
out the mains cable!
Before changing the cutting heads, the cutting wheel, the pipe deburrer, always switch
off the machine and pull out the mains plug (de-energised operation!)!
After it has been switched off, the machine still coasts for a while until it comes to a
standstill.
Do not touch any parts before the machine is completely stationary and the mains plug
has been pulled out!
If the machine is being cleaned, maintained, inspected or repaired , it is essential to
switch it off and to pull out the mains plug (de-energised operation)!
Always avoid uncontrolled starting-up of the machine. Risk of injury and accidents!
Before setting up the thread-tapping machine, read these operating instructions through
carefully and in full. You must fully understand the warnings, instructions and lists they
contain concerning fault-free, safe operation and operating the machine, as well as
those relating to your safety!
Keep the operating instructions in a clean, dry place and within easy reach. If the used
machine is sold, European regulations dictate that these operating instructions must
always be given to the purchaser!
In the case of the threaded pipes, carry out a pressure test in order to ensure that no gas
or water can escape after the pipes are fitted!
2. Technical data
Art.-No. 5.6050 ROPOWER 50 R, 230 V
Art.-No. 5.6045 ROPOWER 50 R, 110 V
Cutting capacity: BSPT R ¼” … 2”
Speed: 40 rpm under no load
Motor: Single-phase universal motor 1150 W, overload protection
Protection class: I
Frequency: 50/60 Hz
Weight: 44 kg (without accessories)
Dimensions: 535 x 430 x 340 mm (LxWxH)
Thread-tapping head: Automatic tapping head ½” … 2”
Thread jaws: ½” … ¾”, 1” … 2”
Optional ¼” – 3/8” (Art.-no. 5.6369)

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3 Functions of the thread-tapping machine
3.1 Overview / accessories / description
3.1.1 Overview, thread-tapping machine
Overview, control elements (> see front fold-out page):
1 Pipe cutter 5 Oil drainage screw
2 Thread-tapping jaws 6 Feeder hand wheel
3 Internal deburrer 7 Centring chuck
4 Tool carriage 8 Clamping chuck
3.1.2 Overview, automatic thread-tapping head
Overview, control elements (> see front fold-out page):
10 T-handle 13 Selector block
11 Locking lever 14 Cam plate
12 Selector pin 15 screw
3.1.3 Accessories
Use only suitable accessories recommended by ROTHENBERGER Werkzeuge GmbH!
Pipe stand, Height-adjustable, with ball guide, for pipes up to 6”
NIPPEL MAX Spare cutting wheel
For internally clamping D=41 mm, L=19 mm, DA=9 mm
short pipe sections hardened special steel for
manufacturing für machine type
nipples and double nipples - PANDA 40, PANDA 90
size 1/2“…2“, - PISET 3 SG, No. 6
Recycling pipe waste pieces - SUPERTRONIC 2S, 3S, 4S, 2SE,
saves time and money 3SE, 4SE, ROPOWER 50 R
automatic fast clamping
and centring of the RONOL
SYN
pipe pieces for right-hand High-performance thread-tapping fluid
and left-hand thread mineral oil-free, synthetic-based specially
for fast, rational working, developed and approved for drinking
automatic release after water and sanitary installation.
completion of the nipple, 100 % water-soluble, physiologically
hardened, ground harmless.
clamping jaws - in 5-litre plastic canisters
- NIPPEL MAX-Set, complete in sheet RONOL
steel carrying case High-performance thread-tapping fluid
1/2“ • 3/4“ • 1“ • 1 1/4“• 1 1/2“ mineral oil-based, very well suited
for thread-tapping work on all
- Nipple holder materials including stainless steel.
1/2“ • 3/4“ • 1“ • 1 1/4“ • 1 1/2“ • 2“ - in 5-litre plastic canisters
- Sheet steel case
- Plastic inlay

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3.1.4 Functional description
Threads are cut or turned on workpieces such as pipes or rods in the thread-tapping machine ROPOWER 50 R.
The machine consists of:
- a drive motor that rotates the centring chuck (7)
- a clamping chuck (8) for securing the workpiece
- a pipe cutter (1) for cutting the workpiece to length
- an internal deburrer (3)
- a thread-tapping head for making a thread on the workpiece
- an oil pump that lubricates and cools with thread-tapping oil
- a tool carriage (4) guided on both sides with a toothed feed
- a chip collecting and oil trough
- a safety pedal
- a coasting restrictor
4 Preparations for operation
4.1 Scope of delivery
When you receive the machine, check
- that it corresponds to the specifications outlined in your order
- for damage or deformation attributable to accidents or other causes during transport
- that all the ordered articles and accessory parts have been supplied.
If you find any deviations, contact the company that sold you the machine immediately or our sales office.
4.2 Transporting the thread-tapping machine
Bend at the knees when lifting the machine so as to protect your back against over-
stressing.

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Fix the tool carriage so that it cannot move while the machine is being transported. Hold the
machine securely by its base to lift it. Do not hold the machine by its centring chuck or the internal
deburrer when carrying it!
If the machine is transported with the thread-tapping oil still inside, the oil might splash out onto
clothing due to vibrations!
Thread-tapping oil on the surface of the machine makes it slippery. Ensure that it does not slip out
of your hands when you lift it!
4.3 Setting up the machine
Set up the machine in a dry location!
Place the machine on a level surface without spaces or on a flat work bench. The centring chuck must
be higher in relation to other parts of the machine so that no thread-tapping oil can escape via the
pipe being machined and contaminate the floor!
Ensure that there is sufficient space around the machine and in the working area!
If you do not have a clear view of the dangerous area formed by the machine and the
revolving workpiece, the full length of the revolving workpieces must be reduced or the
dangerous area must be safeguarded by a cordon or warning signs!
The safety fixtures must be set up and secured firmly. If supports are used for this
purpose, they must be height-adjustable and sturdy and there must be a sufficient
number of them!
4.4 Electrical connection
Do not place either the machine or workpieces on the connecting cable, otherwise the
cable could be damaged and electrical current could be exposed, presenting an electric
shock hazard!
Never touch the mains plug and mains cable with wet hands. Electric shock hazard!
When connecting the machine to the electricity supply, always ensure that the switch is
set to “OFF” ”, otherwise there is a risk that the machine will start up unnoticed and
unsupervised when the power is connected!
Risk of injury and accidents!
Centring chuck side
Higher Lower

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The power source must be fitted with a residual current-operated circuit breaker so that
electric shocks can be prevented!
It is essential that the voltage on the machine’s rating plate corresponds to the power
source, otherwise the machine could get hot, smoke could develop, start a fire and cause
damage!
Protection against electric shock:
The machine has protection class I. Additional earthing is not necessary!
The integrated overload protection automatically stops the machine in the event of an
overload or power fluctuations! Switching back on is not possible until one minute has
elapsed!
Use the extension cable H07 RN 3 x 1.5 mm2! The cable should not be longer than 30 m!
4.5 The thread-tapping oil
For tapping, use ROTHENBERGER high-performance thread-tapping oil art. no. 6.5010.
This oil is not suitable for tapping drinking water pipes!
Alternatively, you can use ROTHENBERGER high-performance thread-tapping fluid,
art. no. 6.5015.
This fluid is suitable for tapping all pipelines (including drinking water pipelines).
Keep thread-tapping oils out of the reach of children!
Do not thin thread-tapping oil or mix it with other oils! If the thread-tapping oil becomes mixed with
water, it turns milky-white, its quality is reduced and the tapped thread displays lower quality. It is
then recommended to change the oil!
Avoid direct sunlight and store the oil in a dark place!
Close the oil container tight after use in order to prevent the ingress of dirt and water!
ATTENTION PERSONS WITH ALLERGIES!
Thread-tapping oil that lands on the skin can cause skin irritation, inflammation and
allergic reactions!
When handling oil, wear protective clothing and cover exposed skin areas.
If your skin comes into contact with oil, wash it immediately with tap water and soap.
If thread-tapping oil burns onto hot workpiece or tool surfaces, this can produce toxic
vapours or gases (e.g. chlorine gas when red oil burns). If you have accidentally inhaled
this oil mist or oil vapours, go out into the fresh air immediately and consult a doctor
without delay!

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4.6 Checking the thread-tapping oil
When cleaning, servicing, inspecting or repairing the machine, it is essential to switch
it off and pull out the mains plug (de-energised operation)!
xA new machine or a machine that has not been used for an extended period is covered with an oil film to
protect it. Remove this with a clean cloth.
xTurn the rotary handle (6) anti-clockwise in order to move the tool carriage (4) to the clamping chuck (8).
xOn the right side of the machine, fill up with the supplied thread-tapping oil to the level of the sieve mesh.
xEnsure that the machine is still switched off and insert the mains plug back into the socket.
xSwitch on the machine and ensure that the thread-tapping oil runs out of the thread-tapping head to the
cutting jaws. If the right amount of oil is not supplied, regulate it with the oil adjustment screw.
4.7 Setting the supplied thread-tapping oil quantity
When cleaning, servicing, inspecting or repairing the machine, it is essential to switch it
off and pull out the mains plug (de-energised operation)!
xEnsure that the oil tank is filled with oil up to the level of the sieve mesh.
xIf the amount of thread-tapping oil running via the thread-tapping head does not meet the requirements, the
supplied amount must be adjusted with the aid of the oil adjustment screw.
xUndo the locking nut of the oil adjustment screw.
xTurning the oil adjustment screw clockwise increases the amount of oil delivered and turning it anti-clockwise
reduces the amount.
xTighten the locking nut firmly after making the adjustment.
Filter
Rotary handle
Locking nut
More
Less

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4.8 Draining off the oil
It is essential to also observe the safety and disposal regulations in Chapter 8!
5 Operation of the thread-tapping machine
5.1 Clamping the workpieces
The tool carriage can make contact with the frame before the tapping process has ended and the
clamping chuck and the machine can be damaged as a result!
A clearance of at least 70 mm must therefore be maintained between the thread cut on the workpiece
and the clamping chuck!
xMove the pipe cutter (1) and the thread-tapping head up so that they are not in the way and position the
internal deburrer (3) on the rear side.
xInsert the workpiece from the centring chuck side (7) and tighten the centring chuck.
In the case of long or heavy pipes, it is essential to use the pipe support Art. No. 5.6047 in order to
prevent the workpiece wobbling or twisting while it is being turned and to prevent the machine from
tipping over due to the weight of the workpiece! Otherwise, the workpiece and the machine can
become unstable. Make safe the danger area as described in Chapter 4.3!
Clamping chuck
Pipe
Centring chuck Tighten centring
chuck
Insert
workpiece
Oil drainage screw

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xHold the workpiece on the clamping chuck side (8) securely with your right hand and gradually tighten it with
the clamping chuck.
xEnsure that the three clamping jaws are in contact with the workpiece.
xIf the three clamping jaws are not in contact with the workpiece, it will wobble and neither cutting nor thread-
tapping can be performed correctly.
xClamp the workpiece securely and tighten it very firmly.
5.2 Cutting the workpiece with the pipe cutter (1)
Do not touch the cutting surface with bare hands, because it is hot and has sharp edges!
Risk of injury and burning!
If the handle of the pipe cutter (1) is turned with force, the cutting surface of the pipe takes an oval
shape, which makes correct thread-tapping impossible. Therefore, move the handle of the pipe cutter
half a turn per whole pipe rotation!
Clamping chuck
Turn
slowly
Hold workpiece tightly with your right hand
Turn the clamping chuck securely

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xMove the pipe cutter (1) up so that it is not in the way. Turn the feeder hand wheel (6) anti-clockwise in order
to bring the pipe cutter into the position necessary for cutting the workpiece.
xMove the pipe cutter down onto the workpiece and then press the ON switch or press the pedal.
xTurn the handle of the pipe cutter powerfully clockwise and start to cut the workpiece.
xSwivel the pipe cutter down and back again.
xDo not collect the cut pipes in the trough! Take them out of the trough immediately after the cutting process
ends!
5.3 Reaming the workpieces
The cutting tip of the internal deburrer (1) is very sharp! Do not touch it with bare hands!
Risk of cutting and injury!
xReam the complete inner surface of the pipe cut with the pipe cutter (1).
xPull the internal deburrer (3) towards you and insert a pipe if there is not already one in the machine before
separation.
Turn rotary
handle into
cutting position
Lower pipe cutter onto the
pipe
Turn handle
and start
cutting

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xTurn the feeder hand wheel (6) anti-clockwise and gently press the cutting edge of the reamer against the
inside of the pipe in order to ream.
xTurn the rotary handle further and gently press the cutting edge of the reamer against the inside of the pipe in
order to ream.
5.4 Changing the thread size
The thread jaws ½” … ¾” must be used for thread sizes ½” and ¾”.
The thread jaws 1” … 2” must be used for pipe sizes 1, 1 ¼”, 1 ½” and 2”.
To change the thread sizes from ½” and ¾” to 1”, 1 ¼”, 1 ½” and 2” and vice versa, the thread jaws in the
thread-tapping head must also be changed as described in the following chapters.
5.5 Removing and installing the thread jaws from and in the thread-tapping head
Removal:
Wear gloves in order to prevent cut injuries to the hands caused by the thread jaws!
xEnsure locking lever is set and remove die head from carriage.

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xPull locking lever toward „A“ to open dies.
xSlide cam plate fully toward „B“ and remove dies.
Installation:
Precise thread-tapping is only possible if the number on the slot of the thread-tapping head
corresponds with the number on the thread jaw!
xInsert dies with the number matched to the number on die head.
xDies can be set at the proper position when the line on dies is fitted to the circumference of die head.
xSlide cam plate toward „C“until a click sound is heard from locking lever.
After changing the thread-tapping jaws, check that they are secure!
After changing the thread-tapping head or replacing the thread-tapping jaws, check that
they are locked securely in the tool carriage!
Locking lever

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5.6 Changing the thread size
xEnsure that the thread-tapping head is on the tool carriage and that the thread jaws correspond to the thread
size.
xInsert the selector pin into the selector block with the necessary thread size.
xThe size is shown on the respective selector block.
xPush T handle towards “D” to set dies.
5.7 Tapping threads
To protect your hands, the thread-tapping machine is fitted with a safety pedal!
The safety pedal has an Emergency Stop switch function!
xIf there is a dangerous situation, press the safety pedal right down. This stops the machine.
xTo restart the machine, press the release button on the side of the safety pedal.
Be careful that you do not crush your hands when lowering the thread-tapping head!

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Do not use force when working on the machine so that the motor cannot come to a
standstill because of an overload, for example caused by worn thread jaws!
Use only raw material that is in perfect condition for tapping threads.
If you use deformed and / or pipes cut off at an angle, it is not possible to tap threads that conform
to the relevant standards!
To guarantee precisely ground threads, follow the instructions below:
Use the thread-tapping head and the corresponding thread-tapping jaws that matches the thread
size! Secure the thread-tapping head correctly on the tool carriage.
Do not place the thread-tapping head directly and unprotected on the floor and handle it with care!
Ensure that the thread-tapping oil runs on the thread-tapping jaws!
xLower the thread-tapping head and insert the T handle, pressing in fully in the “B” direction until the thread-
tapping jaws engage in the working position
xSwitch on the machine with the pedal, turn the rotary handle anti-clockwise so that the thread jaws press onto
the workpiece.
xRelease the rotary handle when 2 to 3 thread turns are cut.
xThe thread-tapping jaws open automatically via a longitudinal stop lever when the thread has been fully cut.
xSwitch off the machine by taking your foot off the safety pedal.
Press
Rotate the rotary handle to cut 2 to 3
thread turns
Rotary handle

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5.8 Setting the thread length
The thread length was set by the manufacturer but can be changed if required.
xHold set pin with a slot screwdriver and loosen hex nut.
xTurning set pin toward „E“, makes shorter threads and turning toward „F“ makes longer threads. The thread
length will be changed about 2mm by half turn.
xHold set pin with a slot screwdriver not to turn it and tighten hex nut.
5.9 Setting the thread depth
xSet location plate to location block which is not fort he size to be adjusted.
xLoosen the screw and move location block to adjust the thread depth.
xSliding toward „G“ makes deeper threads and sliding toward „H“ makes shallower threads The thread depth
will change 1,5 to 2 mm threads by one scale.
xWith the aid of a measuring instrument, check the cut pipe for a tapered thread etc. and correct the setting if
necessary.