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