Rotabroach Cobra CM/200/1 Bedienungsanleitung

Cobra

Magnetic Drilling Machine

Models CM/200/1 & CM/200/3

OPERATOR’S MANUAL

Rotabroach, Imperial works, Sheffield Road, Tinsley, Sheffield S9 2YL. England.

Tel: (++44) 0114 221 2500 Fax: (++44) 0114 221 2560

Email: info@rotabraoch.co.uk Web: www.rotabroach.co.uk

A MEMBER OF THE OSL GROUP OF COMPANIES

This machine (Serial No ) is CE approved.

RLL233

RLL233 Issue 4 Aug 2007

CONTENTS OF THE MANUAL.

Page

[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]

[9]

[10]

[11]

[12]

[13]

[14]

Specification of machine.

General procedures and safety measures.

Operating instructions.

Extension cable selection.

Mounting of cutters.

Cutters and pilots.

Remedies for hole making problems.

Wiring diagram.

Exploded view and component parts of complete machines.

Exploded view and component parts of gearbox and motor units.

Pipe adapter kit.

Wiring of mains plug.

Cutting Speeds.

Cable replacement.

List of Contents with Magnetic Drill Unit

Check

List

RD4329

Safety Strap

YES/NO

RA356

Pilot

YES/NO

RA359

Pilot

YES/NO

RA3013

Pilot

YES/NO

RA3030

Pilot

YES/NO

RA3047

Pilot

YES/NO

RA3057

Pilot

YES/NO

RD4088

4mm A/F Tee Handled Hexagon Key

YES/NO

RD4152

3mm Hexagon Key

YES/NO

RLL233 Issue 4 Aug 2007

[1] ROTABROACH MAGNETIC DRILLING MACHINE

MODELS CM/200/1/ & CM/200/3

Maximum hole cutting capacity in .2/.3C steel = 65mm dia. x 50mm deep

Arbor bore = 19.05mm (3/4") dia.

Motor Unit

Voltages

110v

230v

normal full load

14 A

1400 W

6 A

1400 W

Electro Magnet

0.6A

69W

0.3A

69W

Size

180mm long

90mm wide

Tractive 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.

1200kgs

Total Load (magnet + motor)

1469 W

Overall Dimensions

Height - maximum extended

550mm

Height - minimum

470mm

Width (including Hand wheel)

200mm

Length Overall (including Guard)

270mm

Nett Weight

16kgs

Maximum hand/arm vibration magnitude (measured at

handle during operation in accordance with ISO5349,

using a 22mm cutter through 13mm MS plate)

0.82 m/s_

Estimate of likely daily vibration exposure. Operation

30 holes @ 2 minute/hole.

0.29m/s_ A(8)

Average noise level during cutting at operators ear

position.

89dB(A)

Ear defenders must be worn when operating this 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 25-60Hz 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

RLL233 Issue 4 Aug 2007

READ BEFORE USING THE MACHINE

[2] SAFETY PROCEDURES

•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 gases. Failure to do so may result in

personal injury.

•ALWAYS SECURE THE MACHINE WITH THE SAFETY STRAP - PART NO.

RD4329 BEFORE STARTING TO OPERATE - for the user's protection in case of power

failure or the magnet's breaking loose whilst in use. Failure to do so may result in

personal injury.

•ALWAYS WEAR APPROVED EYE AND EAR PROTRCTION WHEN THE

EQUIPMENT IS IN OPERATION. Failure to do so may result in personal injury.

•Disconnect from the power source when changing cutters or working on the machine.

•When changing cutters, or removing swarf, ALWAYS wear approved gloves.

•ALWAYS ENSURE CUTTER RETAINING SCREWS ARE SECURE - they sometimes

vibrate loose when the machine is in continuous use.

•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 which might have

gathered around the cutter and arbor before proceeding with the next hole.

•Before operating the machine, always remove tie, rings, watches and any loose

adornments which might entangle with the rotating machinery.

•Should the cutter become 'fast' in the workpiece, stop the motor immediately to prevent

personal injury. Disconnect from the 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 trying to drill a hole.

•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 drip on to

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.

RLL233 Issue 4 Aug 2007

•On completion of the cut, a slug will be ejected. DO NOT operate the machine if the

ejected slug may cause injury.

[3] 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, 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, 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.

•Always cut overlapping holes as illustrated above – do not use excessive pressure and ensure

cutting fluid is reaching teeth of the cutter.

•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 slide and arbor support bearing.

•Cutter breakage is usually caused by insecure anchorage, a loosely fitting slide or a worn bearing

in the arbor support. (Refer to routine maintenance instructions).

•Only use approved cutting fluid. Rotabroach cutting fluid has been specially formulated to

maximise the cutters performance. It is available in 1 litre (RD208), 5 litre (RD229), and 25 litre

(RD220) containers.

RLL233 Issue 4 Aug 2007

SPEED SELECTION

The machine is equipped with two speed ranges, High, and Low, and a stepless variation of

each range.

The speed range is changed by the rotary change switch located on the gearbox side. Do not

change gear while the motor is in motion.

The stepless variation is adjusted by rotating the disk located on top of the motor. The disk is

graduated into six numerically designated segments.

Before cutting holes the work piece material specification must be determined to facilitate the

correct cutting speed selection (See section 13 Cutting speeds). Site conditions, eg diameter

and condition of cutter, material condition, material thickness, etc must also be taken into

account when determining the suitable cutting speed. The speed and feed rate must

continuously be monitored and adjusted to ensure optimum cutting conditions prevail.

[4] EXTENSION CABLE SELECTION

The machines are factory fitted with a 3 metre length of cable having three conductors

1.5mm_

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 1.5mm_

For 230v supply: 26metres of 3 core x 1.5mm_ or

17metres of 3 core x 1.0mm_

ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE WHEN

CHANGING CUTTERS.

[5] MOUNTING OF CUTTERS

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.

Take appropriate pilot and place through hole in shank of cutter. Insert shank of cutter into

3/4" dia. bore of arbor, ensuring alignment of two drive flats with socket screws RD4066.

Tighten both screws using hexagon key.

RLL233 Issue 4 Aug 2007

[6] CUTTERS AND PILOTS

Diameter. Pilot type.

12 RA3057

13 -18 RA359

19 - 52 RA3047

12 RA3013

13 -17 RA3030

18 - 65 RA356

18 - 36 RA3047

12 SRA3057

13 - 52 SRA25

12 SRA3013

13 - 65 SRA50

18 - 36 SRA25

SCRWC

SRC, SRCV

SRCL, SRCVL

CRWC

RCL, RCVL

Cutter & Pilot relationship.

Cutter designation.

RC, RCV

RLL233 Issue 4 Aug 2007

[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 of

magnet

Swarf or dirt under magnet

Irregularity on magnet face or

work-piece

Insufficient current going to

magnet during drilling cycle

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 only

imperfections flush to surface

Confirm power supply and output

from control unit.

2) Cutter skips out of

centre-punch mark at

initiation of cut

Magnetic base is not holding

effectively

Worn arbor bearing and/or

ejector sleeve

Too much feed pressure at

start of cut

Cutter is 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 arbor bearing

support bracket or loose gib

adjusting set screws

See causes and remedies above

Replace! Only a few thousandths

wear permissible.

Light pressure 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

RLL233 Issue 4 Aug 2007

Problem

Cause

Remedy

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

Incorrect speed selection.

Re-sharpen or replace

Clean work-piece. Take care not to

start a cut on swarf

Lubricate gib and/or adjust grub

screws

Clear cutter

Select appropriate speed.

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

Incorrect speed selection.

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 slide-way

Retighten

Fill arbor with an oil of light

viscosity and check to be sure 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

Select appropriate speed.

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

RLL233 Issue 4 Aug 2007

[8] WIRING DIAGRAM

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