Rotabroach Element 40 Perm Magnetic Drill User Manual (+ PDF)

Contents hide

1 Element 40 PERM Magnetic Drill

2 Product Information: Magnetic Drilling Machine

2.1 Specifications:

2.2 Contents of the Manual:

3 Product Usage Instructions:

3.1 Documents / Resources

3.1.1 References

Element 40 PERM Magnetic Drill

Product Information: Magnetic Drilling Machine

The Element 40 PERM magnetic drill by Rotabroach is designed to
drill holes in ferrous metals. It is CE approved and intended for
use in various applications such as fabrication, construction,
railways, petrochemical, etc. The drill is equipped with a magnet
that holds it in place while functioning.

Specifications:

Maximum hole cutting capacity in .2/.3C steel = 40mm dia. x
50mm deep
Arbor bore = 19.05mm (3/4) dia.
Motor Unit Voltages: 110V 50-60Hz and 230V 50-60Hz
Power: 1200 W
Dimensions: 210mm long, 90mm wide
Force: 5000N
Stroke length: 530mm
Height (max/min): 450mm/185mm
Width: 394mm
Weight: 13kgs

Contents of the Manual:

Intended use
General safety rules
Information plate symbols
Specification
Operational safety procedures
Operating instructions
Control panel operation
Gear selection
Extension cable selection
Mounting of cutters
Capstan operation
Remedies for hole making problems
Wiring diagram
Exploded view of complete machines
Exploded view of gearbox and motor units
Control panel parts and list
Fitting the chuck
Maintenance checks
Trouble shooting
Cutter selection, speeds and feeds
Warranty and CE statements

Product Usage Instructions:

Step 1: Place the magnetic drill on the surface
to be drilled and switch on the magnet.

Step 2: Ensure that the drill bit is securely
in place and adjust the depth stop to the desired depth of cut.

Step 3: Select the appropriate gear for the
material being drilled and adjust the speed to match the diameter
of the cutter being used.

Step 4: Put on eye protection and ear defenders
before starting the machine.

Step 5: Press the start button and allow the
machine to reach full speed before starting to drill.

Step 6: Keep the drill bit lubricated with
appropriate coolant during drilling.

Step 7: After drilling, switch off the machine
and remove the drill bit from the magnetic drill.

Step 8: Clean the machine and store it in a dry
place.

Note: Always follow the operational safety procedures mentioned
in the manual and wear appropriate personal protective equipment
while using the machine. Any deviation from the intended use of the
machine may void the warranty.

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Magnetic drilling machine
Model Number Element40/1PERM & Element40/3PERM
This machine (Serial Number ………………………) is CE approved.
OSL Cutting Technologies Burgess Road
Sheffield, South Yorkshire United Kingdom S9 3WD
1

Tel: +44 (0) 114 2212 510

Fax: +44 (0) 114 2212

563

Email: [email protected]

Website:

www.rotabroach.co.uk

Thank you for purchasing our Element 40 PERM magnetic drill.

We would really like your feedback on the machine.

Other Products by Rotabroach:

Thank you for your purchase of our product.
2

CONTENTS OF THE MANUAL.

Page

1) Intended use

2) General safety rules

3) Information plate symbols

4) Specification

5) Operational safety procedures

6) Operating instructions

7) Control panel operation

8) Gear selection

9) Extension cable selection

10) Mounting of cutters

11) Capstan operation

12) Remedies for hole making problems

13) Wiring diagram

14) Exploded view of complete machines

15) Exploded view of gearbox and motor units

16) Control panel parts and list

17) Fitting the chuck

18) Maintenance checks

19) Trouble shooting

20) Cutter selection, speeds and feeds

21) Warranty and CE statements

P/N RD4329

Safety Strap

List of Contents with Magnetic Drill Unit

RD4088 RD4152 RD33153 RD4230 RD43099 RDA3105 RDB3066

4mm A/F Tee Handled Hexagon Key 3mm Hexagon Key Drill Chuck Adaptor 6mm Hexagon Key Drill Chuck and key Safety Glasses Carbon Brush

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! Read all safety warnings, instructions, illustrations, and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury. Save all warnings and instructions for future reference. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. Work area safety Keep work area clean and well lit. Cluttered or dark areas invite accidents. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. Electrical safety a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. b) Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
f) If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock. NOTE The term “residual current device (RCD)” can be replaced by the term “ground fault circuit interrupter (GFCI)” or “earth leakage circuit breaker (ELCB)”. Personal safety a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury. b) Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.
4

c) Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents. d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury. e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair and clothing away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts. g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards. h) Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second
5

Power tool use and care a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. c) Disconnect the plug from the power source and/or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users. e) Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. g) Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation. h) Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
Service Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained
3) INFORMATION PLATE SYMBOLS

1. Refer to the user manual for operational and safety issues regarding 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.

4)SPECIFICATION

Maximum hole cutting capacity in .2/.3C steel = 40mm dia. x 50mm deep

Arbor bore = 19.05mm (3/4″) dia. Motor Unit Voltages Normal full load Size
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. Overall Dimensions Height – maximum extended Height – minimum Width (including Capstan fitting) Length Overall (including Guard) Nett Weight
Vibration total values (triax vector sum) in accordance with EN62841-1:
Level of sound pressure in accordance with EN62841-1:

110V 50-60Hz

230V 50-60Hz

1200 W

210mm long

90mm wide

5000N

530mm

450mm

185mm

394mm

13kgs

Element 40/1PERM Element 40/3PERM

Vibration emission value Vibration emission value

(ah):2.746m/s2

(ah):2.466 m/s²

Uncertainty(K):1.5m/s² Uncertainty(K):1.5m/s²

Sound pressure(LpA): Sound pressure(LpA): 89.6

90.6 dB(A)

dB(A)

Acoustic power(LwA): 103.6 dB(A)
Uncertainty(K)3dB(A)

Acoustic power(LwA): 102.6 dB(A)
Uncertainty(K)3dB(A)

Vibration and Noise
The declared vibration total value(s) and the declared noise emission value(s) have been measured in accordance with a standard test method and maybe used for comparing one tool with another.
The declared vibration total value(s) and declared noise emission values(s) may also be used in a preliminary assessment of exposure.
The vibration and noise emissions during actual use of the power tool can differ from the declared total value depending on the ways
in which the tool is used and especially what kind of workpiece is being processed The need to identify safety measures to protect the operator that are based on an estimation of exposure in the actual
conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched off and when it is running
idle in addition to the trigger time).

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 to 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
8

Element 40 PERM Manual

Original instructions

5) OPERATIONAL SAFETY PROCEDURES

Aug 2021

READ BEFORE USING THE MACHINE
·Always take care when lifting and transporting this this machine. The maximum lifting weight for one person is 25kgs. See Fig.1 · 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 RD4329B, 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 approved eye protectors, ear defenders and recommended PPE at ALL times 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. DO NOT operate the machine as the ejected slug may cause injury. · When not in use ALWAYS store the machine in a safe and secure location. · ALWAYS ensure that approved ROTABROACHTM agents conduct repairs.

ALWAYS CARRY THE MACHINE USING THE CARRY HANDLE

Fig.1

Element 40 PERM Manual

Original instructions

6) OPERATING INSTRUCTIONS

Aug 2021

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. · ALWAYS switch off the motor by depressing the MOTOR stop button. · 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 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 do not use water diluted cutting oil. Rotabroach cutting fluid has been specially formulated to maximise the cutters performance. It is available in 1 litre (RD208) and 5 litre (RD229).

COOLANT BOTTLE

1. Unscrew the cap 2. Pour neat oil into the coolant bottle 3. Screw the cap back on the bottle fimly 4. Open the tap. Fig.2

Element 40 PERM Manual

Original instructions

7) CONTROL PANEL OPERATION

Aug 2021

CutSmartTM 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.

CutSmartTM 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.

Element 40 PERM Manual

Original instructions

Aug 2021

8) GEAR SELECTION

The Element 40 PERM magnetic drill is fitted with a 2 speed gearbox. The gear is used to reduce the output speed when using larger cutters.

Up to 30mm diameter cutters, gear position 1 should be used. 30 40mm diameter cutters, gear position 2 should be used

Gear position 1: High speed Up to 30mm diameter cutters

Gear position 2: Low speed 30 to 40mm diameter cutters

9) 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. Should the mains cable become damaged and need replacing, please ensure this is carried out only be an approved Rotabroach Engineer.
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.

10) 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:
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 RD4066.
Take appropriate pilot and place through the hole in cutter shank. Insert shank of cutter into bore of arbor, ensuring alignment of two drive flats with socket screws.
Tighten both screws using hexagon key.

Element 40 PERM Manual 11) CAPSTAN OPERATION

Original instructions

Aug 2021

The quick release capstan is a feature offers 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.

12) REMEDIES FOR HOLE MAKING PROBLEMS

Problem
1) Magnetic base won’t hold effectively

Cause 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.

2) Cutter skips out of centrepunch 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.

Remedy 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. 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.

Cutter is dull, worn, chipped or incorrectly sharpened.

Replace or re-sharpen. Sharpening service is available.

Poor centre-punch mark; weak pilot spring; pilot not

centred in centre-punch mark.

Improve centre-punch and/or replace worn parts

3) Excessive drilling pressure

Worn or bent pilot, worn pilot hole.
Loose bolts on motor bushing support bracket, main casting or loose gib adjusting set screws. Incorrectly re-sharpened, worn or chipped cutter.

Replace part or parts
Adjust where necessary Re-sharpen or replace.

Element 40 PERM Manual

Original instructions

Aug 2021

required

Coming down on swarf lying on surface of work-

Take care not to start a cut on swarf.

piece.

Gibs out of adjustment or lack of lubrication.

Adjust setscrews and lubricate.

4) Excessive cutter breakage

Swarf accumulated (packed) inside cutter. 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

Clear cutter. 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 use for the cutter.

5) Excessive cutter wear

See cause and remedy above Incorrectly re-sharpened cutter.

Refer to instructions and a new cutter for proper tooth geometry.

Insufficient or spasmodic cutting pressure.

Use sufficient steady pressure to slow the drill down. This will result in optimum cutting speed and chip load.

Element 40 PERM Manual 1
3) WIRING DIAGRAM

Original instructions

Aug 2021

Display Board

Control board
No Function 1 Mains Neutral Input 2 Motor Neutral Output 3 Motor Live Output 4 Mains Live Input

Wire Colour Blue Black Red Brown

No Function

A Motor ‘Stop’ Switch 0V

B Motor ‘Stop’ Switch +5V

C Motor ‘Start’ Switch 0V

D Motor ‘Start’ Switch +5V

N/A

G Magnet ‘ON’ LED +5V

H Magnet ‘ON’ LED +5V

I Magnet ‘ON’ LED 0V

N/A

L Motor ‘Stop’ LED 0V (Red)

M Motor ‘Stop’ LED +12V (Red)

N Motor ‘Start’ LED 0V (Green)

O Motor ‘Start’ LED +12V (Green)

Wire Colour White White White White
White+ Green White+ Red White+ Brown
White White White White

Element 40 PERM Manual

Original instructions

14) EXPLODED VIEW OF MACHINE

Aug 2021

Element 40 PERM Manual PARTS LIST

Original instructions

Aug 2021

Item# 1 2 3 4 5 6 7
8
9 10

Rotabroach P/N RD43131 RD45607 RDB3032 RDB3118 RDA4201 RDC4004 RDB3037
RDB2034/1(110V) RDB2034/3(230V)
RD45624 RDB3013

RDB3117

RD4078

RD4079

RD4277

RD4207

RD4098

RDA4005

RDA4021

RDA3001

RD45622

RDB3025PERM

RD4312

RDA3092

RDA4006

RDA4004

RDA4068

PA2R7TS LIST RDA4029

RD33105

RDA3038

RDB3035

RD4092

RD4091

RDB3027

RDA3037

RDB2013

RDA4204

RDA4205

RDB3045

Description Screw M5×16 CSK HD
M5 CSK Washer Guard support Slide channel
Screw M4×14 BTTN HD Screw M4×8 BTTN HD
Element E40 Guard
Motor assembly
Needle bearing HK3516 Bearing bracket
Magnet
Washer spring washer Screw M8×50 CAP HD Spring washer Screw M6×20 CAP HD
Cable bush Screw M4×8 BTTN HD
Main housing Straight pin
Right side panel Grub Screw M6×12
Bush Capstan Washer
Circlip Coolant bottle assembly Screw M6×16 CAP HD
Gib support strip Gib strip Slide
M5 Shakeproof washer Screw M5×22 CAP HD
Rack Adjustable gib strip
Chain Screw M3×8 CSK HD
M3 Nut Cable chain attachment

Qty/pcs 2 2 1 1 2 1 1
1
1 1
1
2 2 2 4 4 1 17 1 2 1 5 2 2 2 1 1 1 1 1 4 4 1 1 1 8 4 2

Element 40 PERM Manual

Original instructions

Aug 2021

RDA4206

Screw M4×12 CSK HD

RDA5008

Handle insert

RD4206

Screw M6×38 CAP HD

RD4069

M4 Washer

RD4068

M4 nut

RD45604

Earth lable

RDB3026PERM

left side panel

RDA3012

Intermediate gear shaft

RDA4070

Cable clamp

RDA4071

Screw M4×18CAP HD

RDA2008

Capstan arm

RDA3015

Capstan Hub

RDB2031/1

RDB2031/3

PCB

RDB2034/1

RDB2034/3

Control panel assembly

RDA3072(230V) RDA3071(110V)

Power chord

RD4329

Safety belt

RD4088

4mm hexagonal spanner

RD43099

Chuck

RD33153

Adapter

RDA3105

Safety glass

RD4152

3mm hexagonal spanner

RD4230

6mm hexagonal spanner

RDB3066

Carbon Brush(Pair)

Element 40 PERM Manual

Original instructions

15) EXPLODED VIEW OF MOTOR AND GEARBOX

Aug 2021

Element 40 PERM Manual PARTS LIST

Original instructions

Aug 2021

8.1

RD4056

Circlip

8.2

RA354

Button

8.3

RA3118

Spring

8.4

RDB3119

Arbor

8.5

RD4066

Grub Screw M8×8

8.6

RDB3020

Arbor spindle

8.7

RD43304

Oil seal

8.8

RDA4037

Fluid lever

8.9

RDB3005

Gear box

8.1

RD45614

Straight Pin

8.11

RDB4008

Spring

8.12

RDB3030

Gear lever

8.13

RDB4006

Gear lever M4 shoulder bolt

8.14

RDB4003

Tapping Screw ST4.8×45

8.15

RDB4001

Needle bearing HK0810

8.16

RDB4002

Washer

8.17

RDB3049

Helical gear 31T 1.25M 15HA 30PA

8.18

RDB3043

17 tooth gear

8.19

RDB3050

Key steel 4×4×16

8.20

RDB3047

Gear axel

8.21

RM17134

Rolling bearing 608

8.22

RDB2022

Dual gear

8.23

RDB3046

Gear axel

8.24

RDB3048

Key steel

8.25

RDB4004

Gear shaft washer 10mm ID

8.26

RDB4005

Needle bearing HK1010

8.27

RDB2010

Gear lever shaft

8.28

RD43305

Rolling bearing 6003 RS

8.29

RD43306

Circlip

8.3

RDB2018

Drive gear assembly

8.31

RD43310

Circlip

8.32

RDB3031

Oil baffle plate

8.33

RDB3006

Gear plate

8.34

RD45522

Rolling bearing 6001 RS

8.35

RDB3060/3(230V) RDB3060/1(110V)

Armature

8.36

RD43603

Rolling bearing 629 RS

8.37

RDB3069

Bearing Sleeve

8.38

RDB5004

Baffle plate

Element 40 PERM Manual

Original instructions

8.39

RD43625

8.4

RDB3061/3(230V) RDB3061/1(110V)

8.41

RDB3065

8.42

RDB3068

8.43

RDB5002

8.44

RDA5018

8.45

RDA3069

8.46

RD35617

8.47

RD45613

8.48

RDA4034

8.49

RD33616

8.5

RDB3066

8.51

RD33614

8.52

RDB5003

8.53

RDA4035

Tapping screw ST4.2×65
Field coil
Lead wire Motor wire Motor housing Wire box cover capacitor Terminal Screw M3×6 BTTN HD Tapping Screw ST2.9×8 Brush cap
Brush Brush hold Top Cap Tapping Screw

Aug 2021
2
1
2 1 1 1 1 2 4 4 2 2 2 1 2

Element 40 PERM Manual

Original instructions

16)CONTROL PANEL AND PARTS LIST

Aug 2021

1 RDA4052

2 RDA4051

3 RDC4093

4 RDA4036

5 RDB3121

RDB3100PERM (110V) / RDB3101PERM (230V)

7 RDA4019

8 RDC4099

9 RDA4205

10 RDA4083

11 RDB4010

Red Motor Switch

Green Motor Switch

Green LED

Screw M3 X 12 BTTN HD

Control Panel Cover

Control Plate

Nylon Spacer

Array Board

M3 Nut

Connection line

17
22

Element 40 PERM Manual

Original instructions

Aug 2021

17) FITTING THE CHUCK · To remove the arbor lay the machine on its side. · Unscrew the two grub screws at the top of the arbor. · When the arbor has become detached from the spindle this can then be removed. · Remove the arbor support bracket and guard with the arbor retained. · Mount the chuck using the chuck adaptor RD33153. · Replacing the chuck is the reverse sequence.
18) 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.

Description Visual check of machine for damage Operation of machine
Check brush wear Check magnetic base Check alignment of the machine Check grease Check armature

Every operation X X X

1 week 1 Month
X X X X

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 the original length, the brushes should be changed. Failure to do so may cause damage to the
23

Element 40 PERM Manual machine.

Original instructions

Aug 2021

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.

Element 40 PERM Manual

Original instructions

19) TROUBLE SHOOTING

Magnet and motor do not function Magnet does function, the motor does not Magnet does not function, the motor does

– Damaged or defective wiring – Defective fuse – Defective magnet switch – Defective control unit – Defective power supply – 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 – Defective magnet

Hole cutters break quickly, holes are bigger than the hole cutter Motor running roughly and/or seizing up Motor making a rattling sound Motor humming, big sparks and motor has no force Motor does not start or fails. Guiding takes a great deal of effort Insufficient magnetic force
Frame under voltage Fuse blows when magnet switch is turned on
Fuse blows when motor is started up
Rotation system free stroke too long

– Play in the guide – Bent spindle – Shaft extending from the motor is bent – Pilot bent – Bent spindle – Shaft extending from the motor is bent – Triangular guide not mounted straight – Dirt between spindle and triangular guide – Gear ring (bottom of the armature) worn out – Gear(s) worn out – No grease in gear box – Armature damaged – Field burned – Carbon brushes worn out – Damaged or defective wiring – Damage to armature or field coil – Damaged or defective brushes – Guide is set too tight – Guide is dry – Guide/gear- rack/rotation system is dirty or damaged – 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 – Damaged / defective wiring – Defective magnet – Motor seriously dirty – Damaged or defective wiring – Wrong value fuse – Defective magnet switch – Defective control unit – Defective magnet – Damaged or defective wiring – Wrong value fuse – Motor running roughly – Defective armature and / or field – Carbon brushes worn out – Defective control unit – Loose or defective gear-rack – Defective rotation system

Aug 2021

Element 40 PERM Manual

Original instructions

20) CUTTER SELECTION AND SPEEDS

Aug 2021

Material
Mild and free cutting steels
Mild and free cutting steels
Steel angle and joists
Steel angle and joists Plate and sheet steel Plate and sheet steel
Aluminium Aluminium
Brass Brass Cast iron Cast iron Stainless steel Stainless steel Stainless steel Rail track Tool steel Die Steel

Material Hardness
<700N/mm²
<850N/mm²
<700N/mm² <850N/mm² <700N/mm² <850N/mm² <750Nmm² <850N/mm² <700N/mm² <850N/mm² <700N/mm² <850N/mm² <700N/mm² <850N/mm² >850N/mm² >850N/mm² >850N/mm² >850N/mm²

Cutter
RAP or RAPL
SRCV or SRCVL
RAP or RAPL SRCV or SRCVL
RAP or RAPL SRCV or SRCVL
RAP or RAPL SRCV or SRCVL
RAP or RAPL SRCV or SRCVL
RAP or RAPL SRCV or SRCVL
RAP or RAPL SRCV or SRCVL CWC to CWCX SCRWC or SCRWCL CWC to CWCX CWC to CWCX

Element 40 PERM Manual

Original instructions

Aug 2021

21) WARRANTY AND CE STATEMENTS
RotabroachTM warrants its machines to be free from faulty materials, 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 RotabroachTMor 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,RotabroachTMwill 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 not 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 RotabroachTM 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 atwww.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 RotabroachTM, in no event shall RotabroachTM 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. ROTABROACHTM RESERVE THE RIGHT TO MAKE IMPROVEMENTS AND MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE
Known and Trusted Worldwide for Quality, Performance and Reliability

Element 40 PERM Manual

Original instructions

Aug 2021

EC Declaration of Conformity Based on the referenced test reports, the below product has been found to comply with the relevant harmonised standard(s) to the directive(s) listed on this verification at the time the tests were carried out.

Name and address of manufacturer:

Rotabroach Ltd Burgess Road, Sheffield Road, Sheffield S9 3WD, United Kingdom

Product tested:

ELEMENT 40/1PERM ELEMENT 40/3PERM

Application of product:

Hole drilling metal

Relevant standards/directives

EN127172001+A12009 The EMC Directive 2014/30/EU The Machinery Directive 2006/42/EC Annex I EN 62841-1:2015 EN55014-1:2017 EN55014-2:2015 EN61000-3-2:2014 EN61000-3-3:2013

Name and Address of Responsible person.
Date: 02th August 2021

Mr Mathew Grey Managing Director Burgess Road, Sheffield S9 3WD United Kingdom
Signature: