Magnetic drilling & tapping machine
Model Number Element 50/1T, Element 50/3T
This machine (Serial Number ...........................) is CE approved.
Rotabroach Ltd
Burgess Road
Sheffield, South Yorkshire
United Kingdom
S9 3WD
Tel: +44 (0) 114 2212 510 Fax: +44 (0) 114 2212 563
Email: info@rotabroach.co.uk Website: www.rotabroach.co.uk
1
Element 50 Manual Original Instructions Aug 2016
Thank you for purchasing our Element 50 magnetic drill.
We would really like your feedback on the machine.
Other products by Rotabroach:
Thank you for your purchase of our product.
2
Element 50 Manual Original Instructions Aug 2016
Page
1)
Intended use
4
2)
General safety rules
4
3)
Information plate symbols
5
4)
Specification
6
5)
Operational safety procedures
7
6)
Operating instructions
7
7)
Control panel operation
8
8)
Tapping function
9
9)
Gear selection
9
10)
Magnet detection
10
11)
Extension cable selection
11
12)
Mounting of cutters
11
13)
Capstan operation
11
14)
Remedies for hole making problems
12
15)
Wiring diagram
13
16)
Exploded view of machine
15
17)
Exploded view of motor and gearbox
18
18)
Control panel parts and list
21
19)
Pipe adapter kit RD2311
22
20)
Fitting the chuck
23
21)
Maintenance
23
22)
Trouble shooting
25
23)
Cutter selection and speeds
26
24)
Warranty statement
27 P/N
List of Contents with Magnetic Drill Unit
RDC4082
Stationary ring
RDC4083
Safety belt
RD4152
3mm hexagonal spanner
RDC4084
13mm Chuck
CA120
Arbor assembly – 6mm hexagonal spanner included
RDC4086
Drift
RDC4087
Arbor shank
RDA3105
Safety glasses
RDC4088
Spare brush-230V
RDC4089
Spare brush-110V
CONTENTS OF THE MANUAL
3
Element 50 Manual Original Instructions Aug 2016
1) INTENDED USE
The intended use of this magnetic drill is to drill holes in ferrous metals. The magnet is used to hold the drill in place
whilst the drill is functioning. It is designed for use in fabrication, construction, railways, petrochemical and any other
applications when drilling ferrous metal. Any deviation from its intended use will not be covered by warranty.
2) GENERAL SAFETY RULES
WARNING! 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. Please read all of these instructions before attempting to
operate the machine.
1. Remove the power supply before carrying out any adjustment, servicing or maintenance.1.
2. Keep work area clear - cluttered areas and benches invite injuries.
3. Consider work area environment;
Do not expose tools to rain.
Do not use tools in damp or wet locations.
Keep work area well lit (500 Lux recommended).
Do not use tools in the presence of flammable liquids or gases.
Ensure there is adequate space to gain access to the plug, mains and motor on/off switches.
4. 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).
5. Keep other persons away. Do not let untrained persons, especially children, touch the tool or the extension cord
and keep them away from the work area.
6. Store idle tools when not in use. All tools should be stored in a dry locked-up place, out of reach of children.
7. Do not apply too much force through the machine. It will do a better and safer job at the feeds for which it was
designed.
8. Use the right tool;
Do not force small tools to do the job of a heavy duty tool.
Do not use this tool for purposes not intended: e.g. do not use the magnetic drill to cut tree logs.
9. 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 a protective hair covering to contain long hair. This will reduce the risk of entanglement.
10. Use protective equipment when using this machine;
Use safety glasses to prevent debris from damaging eyes.
Use ear defenders or ear plugs for hearing protection.
Use face or dust masks if cutting operations create dust.
Use protective gloves to prevent swarf or debris cutting the skin.
11. When using the drill, always ensure a safe operating distance from any swarf and do not reach into the cutting
area, or near the cutter, when the machine is running.
12. Connect dust extraction and collecting equipment, if devices are provided, ensuring these are properly connected
and used.
13. Do not abuse the cord; never pull the cord to disconnect it from the socket. Keep the cord away from heat, oil and
sharp edges.
14. Secure work where possible, use clamps or a vice to hold the work. It is safer than using your hand.
15. Do not overreach! Keep proper footing and balance at all times.
16. Maintain tools with care;
Keep cutting tools sharp and clean for better and safer performance.
Regularly check the machine for any wear or damage.
Ensure the machine is clean and free from debris prior to use.
4
Element 50 Manual Original Instructions Aug 2016
Remove from the mains prior to any maintenance.
Follow instructions for lubricating and changing accessories.
Inspect tool cords periodically and if damaged have it repaired by an authorized Rotabroach service facility.
Inspect extension cords periodically and replace if damaged.
Keep handles dry, clean and free from oil and grease.
17. Disconnect tools from the power supply when not in use, before servicing or when changing accessories such as
cutters.
18. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool before turning it
on.
19. Avoid unintentional starting. Ensure the magnet is off before plugging the machine in.
20. Use extension leads only intended for outdoor use when the tool is used outdoors.
21. The vibration emissions during actual use can differ from the declared total value depending on the ways in which
the tool is being used.
22. Watch what you are doing, use common sense and do not operate the tool when you are tired. Do not operate
the machine when under the influence of alcohol or any illegal substances.
23. Check for damaged or missing parts before use of the tool; it should be carefully checked to determine that it will
operate properly for its intended function.
24. The use of any accessory or attachment, other than ones recommended in this instruction manual, may present a
risk of personal injury.
25. Have your machine repaired by a qualified Rotabroach technician. 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.
26. Never operate the machine if parts are missing or damaged.
27. Never direct jets of water or flammable liquids over the drill.
28. Operator must be physically able to handle the weight of the machine.
29. Operator should be trained in the use of the machine.
3) INFORMATION PLATE SYMBOLS
1
1 2 3 4
1 2 3 4
1 2 3 4
1. Refer to the user manual for operational and safety issues with regard to this machine.
2. Dispose of the machine and electrical components correctly.
3. Eye protection must be worn when operating the machine.
4. Ear defenders must be worn when operating the machine.
5
Element 50 Manual Original Instructions Aug 2016
Motor Unit
Voltages
110V 50-60Hz
230V 50-60Hz
Normal full load
14.9 A
1500W
6.9 A
1500W
Electro Magnet
0.53 A
56W
0.28 A
61W
Size
200mm long
98mm wide
Holding Force at 20°C with 25mm minimum 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.
13500N
Total Load (magnet + motor)
1556W
1561W
Overall Dimensions
Height - maximum extended
586mm
Height - minimum
446mm
Width (including capstan fitting)
195mm
Length Overall (including guard)
315mm
Nett Weight
15.5kgs 15.2kgs
Element 50/1T
Element 50/3T
Vibration total values (triax vector sum) in accordance with
EN61029-1:
Vibration emission value
(ah):3.562m/s2
Uncertainty(K):1.5m/s²
Vibration emission value
(ah):3.527 m/s²
Uncertainty(K):1.5m/s²
Level of sound pressure in accordance with EN61029-1:
Sound pressure(LpA):
87.0 dB(A)
Acoustic power(LwA):
100.0 dB(A)
Uncertainty(K)：3dB(A)
Sound pressure(LpA):
86.0 dB(A)
Acoustic power(LwA):
99.0 dB(A)
Uncertainty(K)：3dB(A)
4) SPECIFICATION
Maximum hole cutting capacity in .2/.3C steel = 50mm dia. x 50mm deep
Arbor bore = MT2
Ear and eye defenders must be worn when operating this machine. Wear gloves to protect hands when operating the
machine.
These tools are UK designed and manufactured with globally sourced components and conform with the requirements
of EEC Document HD.400.1 and BS.2769/84
Suitable only for a single phase 50-60Hz A.C. power supply
DO NOT USE ON D.C. SUPPLY
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
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Element 50 Manual Original Instructions Aug 2016
5) OPERATIONAL SAFETY PROCEDURES
READ 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.
Ensure the magnet is off before plugging in the machine.
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, gases or in high risk environments. Failure to do so may result in personal
injury.
Before activating the machine, inspect all electrical supply cables (including extension leads) and replace if damaged. Do not
use if there are any signs of damage.
Only use extension cables approved for site conditions.
Before activating the machine, always check the correct function of all operational systems, switches, magnet etc.
Before operating, the machine must be securely restrained to a fixed independent feature by using safety strap RDC4083 and
stationary rings RDC4082. Affix the stationary rings into the magnet, uppermost side hole 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 approved eye protectors, ear defenders and recommended PPE 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.
Use a tool or brush where necessary to remove any swarf or the cutter from the arbor.
Before operating the machine, always ensure cutter-retaining screws are secured tightly.
Regularly clear the work area and machine of swarf and dirt, paying particular attention to the underside of the magnet base.
Always remove tie, rings, watches and any loose adornments that might entangle with the rotating machinery before
operating.
Always ensure that long hair is securely enclosed by an approved restraint before operating the machine.
Should the cutter become stuck 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. Wear safety
gloves to remove the cutter from the arbor.
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 for any damaged or loose parts.
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 be ejected.
When not in use always store the machine in a safe and secure location.
Always ensure that approved ROTABROACH™ agents conduct repairs.
6) OPERATING INSTRUCTIONS
Keep the inside of the cutter clear of swarf. It restricts the operating depth of the cutter.
Ensure that the coolant bottle contains sufficient cutting oil to complete the required operating duration. Refill as required.
Occasionally depress the pilot to ensure cutting fluid is being correctly metered.
To start the machine, follow the control panel operation instructions. The Element machine is fitted with a dual motor
protection system to fully ensure safety and extended life of the motor. The CutSmart protection (found on the control panel)
gives a clear and visible indication to the user of torque being applied to the motor, once the prescribed level is reached the
motor is protected by automatic cut out. To re-start your machine, the operator will simply press the start button again (blue
tapping button should a protection mode occur during tapping). If, however the speed controller protection is activated, this is
torque sensor regulated at a pre-determined value above CutSmart (should CutSmart fail to operate) the operator is required
to press the start button twice to re-activate the machine.
Always switch off the motor by depressing the green start/stop button or blue button depending upon operation. Do not
switch off the motor by pressing the magnet switch.
Apply light pressure when commencing the cut of 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, 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) and may cause excessive heat which may result in inconsistent slug ejection
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 to
make 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 the slide.
Cutter breakage is usually caused by insecure anchorage or a loosely fitting slide (Refer to routine maintenance instructions).
Only use approved cutting fluid. Rotabroach cutting fluid has been specially formulated to maximise the cutters performance.
7
Element 50 Manual Original Instructions Aug 2016
CutSmart™ Technology
Green Zone
Perfect, try to keep in
the green zone for
the best cut and
optimum machine
performance.
Yellow Zone
A little too much
pressure on the drill
ease off to get back
to the green zone.
Red Zone
Overload: Back off
immediately as too
much force will cause
the motor to cut off
if you continue.
CutSmart™ Technology
Designed for you to get the most out of your
machine and your cutters. CutSmart has an
easy to read panel that indicates when you
are drilling with too much force, which will
damage the machine and the cutters.
Allow the cutter to do the work and you will
find that a much smoother hole and faster
drilling time is achieved.
7) CONTROL PANEL OPERATION
8
Element 50 Manual Original Instructions Aug 2016
8) TAPPING FUNCTION
1. Ensure power to the machine, red LED will illuminate (1).
2. Press the magnet switch on (2) to engage the magnet. The LED will light up in either green or
red (3). Depending on the material thickness and magnetic adhesion. Green magnet LED indicates
optimum adhesion achieved. Drilling operation is available.
Warning if red magnet LED is illuminated this indicates optimum adhesion not achieved. Drilling
operation is still available.
3. Use the speed controller on the top cap housing to dictate the speed, always use speeds that
are recommended for the drill size being used.
4. Turn the motor on in the forward direction (4).
5. Drill the hole to the recommended tapping size for the thread to be cut.
6. Without disengaging the magnet replace the drill with the tap.
7. Set the spindle speed to the required tapping speed required.
8. Start the drill spindle in the forward direction (4) and feed the tap into the hole until it begins to
cut. Once cutting the tap will feed itself through, only gentle pressure on the feed handles should
be necessary.
9. Once the tap has threaded the hole the drill should be stopped immediately (4).
10. The drill spindle should then be switched to reverse (5) and the tap can be fed back out of the
hole. Allowing the tap to be safely extracted from the hole at a reduced RPM.
9
Element 50 Manual Original Instructions Aug 2016
Slide Selector Position
Speed Controller Setting
Level 1
Level 6
/\
200/min
500/min
\/
100/min
265/min
Slide Selector Positon Up
Slide Selector Positon Down
9) GEAR SELECTION
The Element 50 magnetic drill is fitted with a 2 speed gearbox. The gear is used to reduce the
output speed when using larger cutters.
10) MAGNET DETECTION
It is advised that when working on thin material a packing piece should be used to increase the
material thickness under the magnet. Working on thin material without a packing piece will reduce
the magnet holding force.
It is advised that the drill is to be operated on ferrous material 12mm thick and above. Damage to
the magnet base, such as pitting, will affect the strength of the magnet holding force.
10
Element 50 Manual Original Instructions Aug 2016
11) EXTENSION CABLE SELECTION
The machines are factory fitted with a 3 metre length of cable having three conductors 1.5mm²
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: 26metres of 3 core x 1.5mm²
ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE CHANGING CUTTERS.
12) MOUNTING OF CUTTERS
The machine has been made to accept cutters having 19.05mm (3/4”) dia. Weldon shanks.
The following procedure is to be used when mounting cutters:
With the machine in the upright position, ensure the Arbor Assembly (CA120) is fully
inserted into Arbor Spindle (RDC4009).
Take appropriate pilot and place through the hole in cutter shank. Insert shank of cutter
into bore of Arbor Assembly, ensuring alignment of two drive flats with socket screws.
Tighten both screws using hexagon key.
13) CAPSTAN OPERATION
The quick release capstan is a feature that offers the user simple dual side operation.
To remove the capstan, simply do the following;
1: Press in the central button on the capstan hub, holding onto the capstan arms.
2: With the button pressed in, pull the capstan away from the main body, holding on to the
capstan arms.
3: Re-insert the hexagonal shaft into the hexagonal slot to attach the capstan.
11
Element 50 Manual Original Instructions Aug 2016
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 the magnet, 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.
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.
Gib strips 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 needs adjustment.
Cutter not attached tightly to arbor.
Insufficient use of cutting oil or unsuitable type of oil.
Incorrect speed
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 grub screws supporting the slide.
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).
Ensure correct gear is used for the cutter.
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.
14) REMEDIES FOR HOLE MAKING PROBLEMS
12
Element 50 Manual Original Instructions Aug 2016
No
Function
Wire Colour
1
Mains Live Input
Brown
2
Speed controller module Lead wire
White
3
Speed controller module Lead wire
Red
4
Mains Neutral Input
Blue
5
Magnet Positive Output
230V Red，110V Blue
6
Magnet Negative Output
Black
7
Field coil Lead wire
Blue
8
Field coil Lead wire
Green
9
Carbon brush Lead wire
Black
10
Carbon brush Lead wire
Brown
15) WIRING DIAGRAM
13
Element 50 Manual Original Instructions Aug 2016
No
Function
Wire Colour
A
Motor 'Reverse' Switch 0V
White
B
Motor 'Reverse' Switch +5V
White
C
Motor 'Forward' Switch 0V
White
D
Motor 'Forward' Switch +5V
White
E
Magnet Switch 0V
White
F
Magnet Switch +5V
White
G
Magnet 'ON' LED +5V
White + Green
H
Magnet 'ON' LED +5V
White + Red
I
Magnet 'ON' LED 0V
White + Brown
J
Power 'ON' LED 0V
White + Black
K
Power 'ON' LED +5V
White + Brown
L
Motor 'Reverse' LED OV (BLUE)
White
M
Motor 'Reverse' LED +12V (BLUE)
White
N
Motor 'Forward' LED 0V (Green)
White
O
Motor 'Forward' LED +12V (Green)
White
14
Element 50 Manual Original Instructions Aug 2016
16) EXPLODED VIEW OF MACHINE
15
Element 50 Manual Original Instructions Aug 2016
Item#
Rotabroach
P/N
Description
Qty/pcs
1
RDC4001
Screw
2 2 RD45607
M5 CSK Washer
2 3 RDC4002
Guard support
1 4 RDC4003
Slide channel
1 5 RDA4201
Screw M4×14 Button Head
2 6 RDB3037
Element E40 Guard
1
7
RDC4004
Screw M4×8 Button Head
1
9
RDC4053
Magnet-230V
1
RDC4054
Magnet-110V
1
10
RD4079
Spring washer
4
11
RDC4055
Screw
2
12
RDA4005
Cable bush
1
13
RDC4056
Screw
4
14
RDC4057
Nut
4
15
RDA4021
Screw M4×8 Button Head
13
16
RDC4058
Right side plate
1
17
RD4098
Screw M6×20 CAP HD
1
18
RDA4029
Screw M6×16 CAP HD
2
19
RDC4104
Spring washer
2
20
RDA3092
Bush
2
21
RDA4006
Capstan Washer
2
22
RDA4004
Circlip
2
23
RDC4059
Screw
10
24
RDC4060
Guide bar
2
25
RDC4061
Slide
1
26
RDC4062
Rack
1
27
RDC4063
Screw
6
28
RDC4064
Chain
1
29
RDA4205
M3 Nut
2
30
RDC4065
Chain
1
31
RDA4204
Screw M3×8 CSK HD
14
32
RDC4066
Screw
1
33
RDC4067
Coolant bottle assembly
1
PARTS LIST
16
Element 50 Manual Original Instructions Aug 2016
Item#
Rotabroach P/N
Description
Qty/pcs
34
RDD4118
Screw M4×12 Button Head
2
35
RDC4068
Screw
2
36
RDC4069
Housing
1
37
RDA5008
Handle insert
1
38
RD4068
M4 nut
4
39
RD45604
Earth label
1
40
RDA4070
Cable clamp
1
41
RDA4071
Screw M4×18CAP HD
2
42
RDD4104
Capstan arm
3
43
RDA3015
Capstan Hub
1
44
RDC4070
Capstan spindle
1
45
RDC4071
Left side panel
1
46
RD4069
Washer
1
47
RDC4073
Screw
2
48
RDC4074
Cable plug assembly-230V
1
RDC4075
Cable plug assembly-110V
1
49
RDC4076
Control panel assembly-E50/3T
1
RDC4077
Control panel assembly-E50/1T
1
50
RDC4080
Tapping screw ST2.9×12(using 110V)
3
51
RDC4081
Clamp (using 110V)
1
52
RDC4082
Stationary ring
2
53
RDC4083
Safety belt
1
54
RD4152
3mm hexagonal spanner
1
55
RDC4084
13mm Chuck
1
56
CA120
Arbor assembly
1
57
RDC4086
Drift
1
58
RDC4087
Arbor shank
1
59
RDA3105
Safety Glasses
1
60
RDC4088
Spare brush-230V
1pair
RDC4089
Spare brush-110V
1pair
17
Element 50 Manual Original Instructions Aug 2016
17) EXPLODED VIEW OF MOTOR AND GEARBOX
18
Element 50 Manual Original Instructions Aug 2016
Item#
Rotabroach P/N
Description
Qty/pcs
8
RDC4005
Motor assembly-230V
1
RDC4006
Motor assembly-110V
1
8.1
RDC4007
Circlip
1
8.2
RDC4008
Oil seal washer
1
8.3
RDC4009
Arbor spindle
1
8.4
RDC4010
Roll Bearing
1
8.5
RDC4011
Flat Key
1
8.6
RDC4012
Tapping Screw
4
8.7
RDB4008
Spring
1
8.8
RDB3030
Gear lever
1
8.9
RDC4013
screw
1
8.1
RDC4014
Gear box
1
8.11
RDC4015
Needle bearing
1
8.12
RDB4004
Gear shaft washer 10mm ID
1
8.13
RDB3048
Key steel
1
8.14
RDB3046
Gear axel
1
8.15
RDB2010
Gear lever shaft
1
8.16
RDB2022
Dual gear
1
8.17
RDB4002
Washer
2
8.18
RDC4016
Needle bearing
2
8.19
RDC4017
Circlip
1
8.2
RDC4018
Big gear
1
8.21
RDC4019
Roll Bearing
1
8.22
RDC4020
Oil seal
1
8.23
RD45614
Straight Pin
1
8.24
RM17134
Rolling bearing 608
1
8.25
RDC4021
Shaft gear
1
8.26
RDC4022
Flat Key
1
8.27
RDC4023
Gear
1
8.28
RDC4024
Oil baffle plate
1
8.29
RDC4025
Inner gear plate
1
8.3
RDC4026
Seal washer
1
8.31
RD45522
Rolling bearing 6001
1
8.32
RDC4027
Armature-230V
1
RDC4028
Armature-110V
1
8.33
RD43603
Rolling bearing 629
1
8.34
RDB3069
Bearing Sleeve
1
8.35
RDC4029
Inductor
1
PARTS LIST
19
Element 50 Manual Original Instructions Aug 2016
Item#
Rotabroach P/N
Description
Qty/pcs
8.36
RDC4030
Baffle plate
1
8.37
RDC4031
Tapping Screw
2
8.38
RDC4032
Field coil-230V
1
RDC4033
Field coil-110V
1
8.39
RDC4034
Lead wire
1
8.4
RDC4035
Lead wire
1
8.41
RDC4036
Motor casing
1
8.42
RDC4037
Lead wire
1
8.43
RD33616
Brush cap
2
8.44
RDC4038
Carbon brush-230V
2
RDC4039
Carbon brush-110V
2
8.45
RD33614
Brush holder
2
8.46
RDC4040
Lead wire
1
8.47
RD35617
Terminal
6
8.48
RD45613
Screw M3×6 Button Head
12
8.49
RDC4041
Speed controller module-230V
1
RDC4042
Speed controller module-110V
1
8.5
RDA4035
Tapping Screw
2
8.51
RDC4043
Top Cap
1
8.52
RDC4044
Tapping Screw
4
8.53
RDA4034
Tapping Screw ST2.9×8
4
8.54
RDC4045
Outlet clamp
1
8.55
RDC4046
Plastic tube
1
8.56
RDC4047
Lead wire(green)
1
8.57
RDC4048
Lead wire(brown)
1
8.58
RDC4049
Lead wire(black)
1
8.59
RDC4050
Lead wire(blue)
1
8.6
RDC4051
Lead wire(red)
1
8.61
RDC4052
Lead wire(white)
1
20
Element 50 Manual Original Instructions Aug 2016
Item#
Rotabroach P/N
Description
Qty/pcs
1
RDA4051
Green Motor Switch
1 2 RDC4090
Blue Motor Switch-Tapping
1 3 RDC4091
Magnet Switch
1 4 RDC4092
Red LED
1 5 RDC4093
Green LED
1 6 RDA4036
Screw M3×12 BTTN HD
2 7 RDD4005
Control Panel Cover
1 8 RDD4006
Control Plate-230V Tapping
1
RDD4007
Control Plate-110V Tapping
1
9
RDA4019
Nylon Spacer
2
10
RDC4099
Array Board
1
11
RDA4205
M3 Nut
2
12
RDC4100
Connection line
1
13
RDC4101
Connection line
1
14
RDD4314/3
E75PCBA-230V
1
RDD4314/1
E75PCBA-110V
1
18) CONTROL PANEL AND PARTS LIST
21
Element 50 Manual Original Instructions Aug 2016
19) 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 of the 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.
22
Element 50 Manual Original Instructions Aug 2016
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
20) FITTING THE CHUCK
The machine comes supplied with an RDC4087 (Arbor Shank) & RDC4084 (13mm
Chuck).
Insert RDC4087 into RDC4009 (Arbor Spindle), ensure a good and tight fit is
achieved.
Insert RD4084 into RDC4087, ensure a good and tight fit is achieved.
Replacing the chuck is the reverse sequence, by utilising RDC4086 (Drift).
21) MAINTENANCE
In order to ‘get the best life’ out of your Rotabroach machine always keep it in good
working order.
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.
Visually check the machine for damage.
The machine must be checked before operation for any signs of damage that will affect the
operation of the machine. Particular notice must be taken to 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.
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 of the original
length, the brushes should be changed. Failure to do so may cause damage to the machine.
23
Element 50 Manual Original Instructions Aug 2016
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 center 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 power supply and switch on the
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 your machine.
Check Armature of the machine.
This should be checked at least once a month to check that there are no 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 but this is normal (this is the part that comes into contact
with the brushes) however, if there are any signs of abnormal damage the part should be
replaced.
24
Element 50 Manual Original Instructions Aug 2016
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 is 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
22) TROUBLE SHOOTING
25
Element 50 Manual Original Instructions Aug 2016
Material
Material Hardness
Cutter
Mild and free cutting steels
<900N/mm²
RAP or RAPL
Mild and free cutting steels
<900N/mm²
SRCV or SRCVL
Steel angle and joists
<900N/mm²
RAP or RAPL
Steel angle and joists
<900N/mm²
SRCV or SRCVL
Plate and sheet steel
<900N/mm²
RAP or RAPL
Plate and sheet steel
<900N/mm²
SRCV or SRCVL
Aluminium
<900Nmm²
RAP or RAPL
Aluminium
<900N/mm²
SRCV or SRCVL
Brass
<900N/mm²
RAP or RAPL
Brass
<900N/mm²
SRCV or SRCVL
Cast iron
<900N/mm²
RAP or RAPL
Cast iron
<900N/mm²
SRCV or SRCVL
Stainless steel
<900N/mm²
RAP or RAPL
Stainless steel
<900N/mm²
SRCV or SRCVL
Stainless steel
>1400N/mm²
CWC to CWCX
Rail track
>1400N/mm²
SCRWC or SCRWCL
Tool steel
>1400N/mm²
CWC to CWCX
Die Steel
>1400N/mm²
CWC to CWCX
Cast Iron
>1800N/mm²
CTCT
Inox
>1800N/mm²
CTCT
Inconel
>1800N/mm²
CTCT
Fine Grain Steel
>1800N/mm²
CTCT
Hardox
>1800N/mm²
CTCT
23) CUTTER SELECTION AND SPEEDS
26
Element 50 Manual Original Instructions Aug 2016
24) WARRANTY STATEMENT
Rotabroach™ warrants its machines to be free from faulty parts, under normal usage of machines, for a
period of 12 months from initial date of purchase. All other parts (excluding cutters) are under warranty for
90 days, 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 is not in accordance with the
operator’s 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 at www.rotabroach.co.uk
The warranty claim must be logged 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 MERCHANTABLITY 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
27
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