TM
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
A MEMBER OF THE OSL GROUP OF COMPANIES
This machine (Serial No
) is CE approved.
RLL233
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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
Electro Magnet
Size
14 A 1400 W 6 A 1400 W
0.6A 69W 0.3A 69W
180mm long
90mm wide
1200kgs
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.
Total Load (magnet + motor)
1469 W
1469 W
Overall Dimensions
Height - maximum extended
Height - minimum
Width (including Hand wheel)
Length Overall (including Guard)
Nett Weight
550mm
470mm
200mm
270mm
16kgs
Maximum hand/arm vibration magnitude (measured at
handle during operation in accordance with ISO5349,
using a 22mm cutter through 13mm MS plate)
Estimate of likely daily vibration exposure. Operation
30 holes @ 2 minute/hole.
0.82 m/s_
0.29m/s_ A(8)
89dB(A)
Average noise level during cutting at operators ear
position.
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
2
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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.
3
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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.
4
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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:
For 230v supply:
3.5metres of 3 core x 1.5mm_
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.
5
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RLL233
Issue 4 Aug 2007
[6] CUTTERS AND PILOTS
Cutter & Pilot relationship.
Cutter designation. Diameter. Pilot type.
12
RA3057
RC, RCV
13 -18 RA359
19 - 52 RA3047
12
RA3013
RCL, RCVL
CRWC
13 -17 RA3030
18 - 65 RA356
18 - 36 RA3047
12
SRA3057
SRC, SRCV
13 - 52 SRA25
12
SRA3013
SRCL, SRCVL
SCRWC
13 - 65 SRA50
18 - 36 SRA25
6
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RLL233
Issue 4 Aug 2007
[7]
REMEDIES FOR HOLE MAKING PROBLEMS
Problem
Cause
Remedy
1) Magnetic base
Material being cut may be too Attach an additional piece of metal
won't hold effectively thin for efficient holding of
magnet
under work-piece where magnet will
be located, or mechanically clamp
magnetic base to work-piece
Swarf or dirt under magnet
Clean magnet
Irregularity on magnet face or Use extreme care, file only
work-piece
imperfections flush to surface
Insufficient current going to Confirm power supply and output
magnet during drilling cycle from control unit.
2) Cutter skips out of Magnetic base is not holding See causes and remedies above
centre-punch mark at effectively
initiation of cut
Worn arbor bearing and/or
ejector sleeve
Replace! Only a few thousandths
wear permissible.
Too much feed pressure at
start of cut
Light pressure until a groove is cut.
The groove then serves as a
stabilizer.
Cutter is worn, chipped or
incorrectly sharpened
Replace or re-sharpen. Sharpening
service is available.
Poor centre-punch mark;
Improve centre-punch and/or replace
weak pilot spring; pilot not worn parts
centred in centre-punch mark
Worn or bent pilot, worn pilot Replace part or parts
hole
Loose bolts on arbor bearing Adjust where necessary
support bracket or loose gib
adjusting set screws
7
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RLL233
Issue 4 Aug 2007
Remedy
Problem
Cause
3) Excessive drilling Incorrectly re-sharpened,
Re-sharpen or replace
pressure required
worn or chipped cutter
Coming down on swarf lying Clean work-piece. Take care not to
on surface of work-piece
start a cut on swarf
Gibs out of adjustment or
lack of lubrication
Lubricate gib and/or adjust grub
screws
Swarf accumulated (packed) Clear cutter
inside cutter
Incorrect speed selection.
Select appropriate speed.
4) Excessive cutter
breakage
Steel swarf or dirt under
cutter
Remove cutter, clean part thoroughly
and replace
Incorrectly re-sharpened or
worn cutter
Always have a new cutter on hand to
refer to for correct tooth geometry,
together with instruction sheet
Cutter skipping
See causes and remedies (2)
Slide-ways need adjustment Tighten slide-way
Cutter not attached tightly to Retighten
arbor
Insufficient use of cutting oil Fill arbor with an oil of light
or unsuitable type of oil
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
Incorrect speed selection.
Select appropriate speed.
5) ) Excessive cutter See cause and remedy above.
wear
Incorrectly re-sharpened
cutter
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
Insufficient or spasmodic
cutting pressure
8
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RLL233
Issue 4 Aug 2007
[8]
WIRING DIAGRAM
9
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RLL233
Issue 4 Aug 2007
[9] EXPLODED VIEW OF COMPLETE MACHINE
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RLL233
[9] Parts list for CM/200/1 & CM/200/3
Component Part No. Item
Guard assembly
Issue 4 Aug 2007
Item
1
Component
RD25501 6.6 Internal washer
RD35522 6.7 Washer
Part No. Item
RD4069 9.6 Chain bush
Component
Part No.
RD4521
RD4018
RD3558
RD25510
RD3505
RD3504
RD3503
RD23303
RD23317
RD33319
RD33320
RD4269
RD25511
RD25513
1.1 Guard
RD4070 9.7 Countersunk set screw
RD4071 9.8 Chain
RD4077 10 Gib strap assembly
RD4312 10.1 Gib support strip
RD4503 10.2 Adjustable gib strip
RD4502 10.3 Static gib strip
1.2 Pan head screw
1.3 Guard bracket
1.4 Spring plunger
1.5 Countersunk screw
RD4077 6.8 Saddle clamp
RD3246 6.9 Pan head screw
RD4346 6.10 Socket set screw
RD4347 6.11 Name plate
2
Bearing bracket assembly
RD25503 6.12 Information plate
RD43301 6.13 Conclamp
2.1 Arbor bearing
RD472
11 Oil bottle assembly
2.2 Bearing bracket
RD35535 6.14 Cable clip
RD45532 11.1 Bottle & bracket
RD33338 11.2 Adjustable ratchet wheel
RD4414 11.3 Tension plate
RD45501 11.4 Socket head set screw
RD4079 12 Control unit assembly (110v)
RD25504 12 Control unit assembly (230v)
RD3014 13 Fascia plate
RD43302 13.1 Shakeproof washer
RD25509 13.2 Pan head screw
RD25504 14 Mains cable assembly (110v)
RD2506 14 Mains cable assembly (230v)
RD4049 15 Magnet base assembly
RD3502 16 Arbor space bracket
3
3
Motor & gearbox assembly (110v)
Motor & gearbox assembly (230v)
RD25551 6.15 Fixed ratchet wheel
RD25553 6.16 Socket head cap screw
RD25502 6.17 Pan head screw
RD4418 6.18 Bush
3.1 Motor cable assembly
3.2 Countersunk screw
3.3 Cable cover
RD33321
7
Capstan arm assembly
3.4 Socket head cap screw
3.5 Washer
RD4091 7.1 Capstan arm
RD4092 7.2 Knob
As required
RD4069
RD4077
RD271
RD272
RD3557
RD3507
RD4517
RD4079
RD4078
RD4098
RD4096
RD4056
RA354
4
Slide assembly
RD25505
RD35521
8
7
Capstan assembly
Capstan arm assembly
4.1 Slide
4.2 Key
4.3 Rack
RD35536 8.2 Capstan hub assembly
RD4048 8.3 Pinion
4.4 Socket head cap screw
4.5 Washer
RD4091 8.4 Pinion shaft collar
RD4092 8.5 Pinion bearing
RD2507 8.6 Pinion circlip
RD403
17 Arbor bracket bolt
5
Housing sub assembly
RM22876 18 Shakeproof washer
RD4098 19 Plain washer
RD4207 20 Magnet fixing screw
RD2505 21 Shakeproof washer
RD4414 22 Circlip
RD4069 23 Button
RD4250 24 Compression spring
RD4045
5.1 Housing
5.2 Tension pin
RD3500 8.7 Socket head cap screw
RD3026 8.8 Spring washer
6
5
Housing assembly
Housing sub assembly
RD25508
9
Cable chain assembly
RD2507 9.1 Socket head cap screw
RD3026 9.2 Shakeproof washer
RD3027 9.3 Hex nut
RD4046 9.4 Washer
RD4068 9.5 Chain fixing bracket
6.2 Earth terminal
6.3 Aluminum scale
6.4 Countersunk set screw
6.5 Hex nut
RA355
RD3515
Issue 4
4.2 Was RD3009
Page 11
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RLL233
Issue 4 Aug 2007
[10] EXPLODED VIEW OF GEARBOX AND MOTOR UNITS
Page 12
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RLL233
Issue 4 Aug 2007
Part list of motor & gearbox(Cobra)
Item
Component
Motor assembly (110v)
Part No. Item
Component
Part No. Item
Component
Part No.
RD45506
RD45503
RD25506
RD25515
RD25514
RD25507
RD35501
RD43324
RD45510
RD35530
RD45521
RD45513
RD45524
RD45516
RD45515
RD45509
RD45514
RD35507
RD35514
RD45518
RD35509
RD45519
RD35512
RD35508
RD45520
RD35513
1
1
2
2
3
3
RD25521 3.7 Speed controller assembly (110v)
RD25523 3.7 Speed controller assembly (230v)
RD23330 7.7 Disk spring
RD23343 7.8 Lock nut
Motor assembly (230v)
Armature assembly (110v)
RD25531 3.8 Screw
RD25533 3.9 End cap
RD25561 3.10 Screw
RD45501
RD35520
RD45529
RD25512
8
5
6
7
Gearbox assembly
Armature assembly (230v)
Gearbox housing assembly
Inner gearplate assembly
Field coil & motor housing assembly (110v)
Field coil & motor housing assembly (230v)
RD25563
4
Motor housing assembly
Clutch assembly
1.1 Socket head cap screw
1.2 Shakeproof washer
1.3 Washer
RD45532 4.1 Motor housing
RD4092 4.2 Bush
RD35516 8.1 Arbor spindle
RD35532 8.2 Coolant elbow
RD35517 8.3 Screw
RD4205 4.3 Brush holder
2
2
Armature assembly (110v)
Armature assembly (230v)
RD25531
5
Gearbox housing assembly
RD25515 8.4 Gear selector
RD35506 8.5 Bush
RD25533 5.1 Gearbox
2.1 Bearing
RD45517 5.2 Seal kit
RD45508 8.6 Circlip
2.2 Armature (110v)
2.2 Armature (230v)
2.3 Bearing
RD35521 5.3 Bearing kit (arbor spindle)
RD35523 5.4 Circlip
RD45511 8.7 Socket set screw
RD45512 8.8 Spring
RD45502 8.9 Steel ball
RD25514 8.10 Circlip
RD45526 5.5 Bearing kit (inter pinion shaft)
2.4 Speed sensor
RD35515
6
Inner gearplate assembly
3
3
4
Field coil & motor housing assembly (110v)
Field coil & motor housing assembly (230v)
Motor housing assembly
RD25561 6.1 Inner gearplate
RD25563 6.2 Bearing
RD35511 8.11 Spring
RD45522 8.12 Gear
RD25512 6.3 Bearing
RD45507 8.13 Bush
3.1 Field coil (110v)
3.1 Field coil (230v)
3.2 Screw
RD35551
7
Clutch assembly
RD25507 8.14 Circlip
RD35553 7.1 Interpinion shaft
RD45525 7.2 Washer
RD4092 7.3 Thrust washer
RD45527 7.4 Gear
RD35505 8.15 Gear selector ring
RD45504 8.16 Snap ring
RD45505 8.17 Gear
3.3 Shakeproof washer
3.4 Socket head set screw
3.5 Carbon brush
3.6 Brush cover
RD35503 8.18 Bush
RD35518 7.5 Bush
RD35502 8.19 Spring
RD35519 7.6 Washer
RD35504
9
Inner cap
Page 13
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RLL233
Issue 4 Aug 2007
[11] 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 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.
• .
Page 14
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RLL233
Issue 4 Aug 2007
[12] WIRING OF MAINS PLUG
The wires of the mains lead are coloured in accordance with the following code:
GREEN and YELLOW
BLUE
EARTH
NEUTRAL
LIVE
BROWN
As the colours of the mains lead of this appliance may not correspond with the coloured
markings identifying the terminals in your plug - CONNECT AS FOLLOWS;
• The wire coloured GREEN and YELLOW must be connected to the terminal
marked E or marked by the earth symbol or coloured GREEN or GREEN and
YELLOW
• The wire coloured BROWN must be connected to the terminal marked L or coloured
RED
• The wire coloured BLUE must be connected to the terminal marked N or coloured
BLACK
In the U.K. fit a fused 13A plug for 230v supply; for 110v supply fit a 15A transformer plug
WARNING - THIS APPLIANCE MUST BE EARTHED!
15
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RLL233
Issue 4 Aug 2007
13] CUTTING SPEEDS.
Typical cutting speeds (RPM) for various materials
Cutter
dia
Surface speed.
15 30
Cutter
dia
Surface speed.
15 30 45
9
45
9
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
239 398 796 1194
220 367 734 1102
205 341 682 1023
191 318 637 955
179 298 597 895
168 281 562 842
159 265 530 796
151 251 503 754
143 239 477 716
136 227 455 682
130 217 434 651
125 208 415 623
119 199 398 597
115 191 382 573
110 184 367 551
106 177 354 530
102 171 341 512
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
73
72
70
68
67
65
64
62
61
60
58
57
56
55
54
53
52
51
50
49
49
48
47
46
45
45
44
122 245 367
119 239 358
116 233 349
114 227 341
111 222 333
109 217 326
106 212 318
104 208 311
102 203 305
99
97
95
94
92
90
88
87
85
84
82
81
80
78
77
76
75
73
199 298
195 292
191 286
187 281
184 275
180 270
177 265
174 260
171 256
168 251
165 247
162 243
159 239
157 235
154 231
152 227
149 224
147 220
99
95
92
90
87
84
82
80
77
75
165 329 494
159 318 477
154 308 462
149 298 448
145 289 434
140 281 421
136 273 409
133 265 398
129 258 387
126 251 377
These speeds should be viewed as a suggested starting point only.
The machine speed may require adjustment to suit the application conditions.
Material
Surface speed (M/min)
Aluminium
Cast iron
60-90
30-50
15-21
15-30
24-30
15-27
9-15
Soft
Hard alloy
Malleable
Mild (460 N/mm_)
(460-770 N/mm_)
(770-1070 N/mm_)
1070-1230 N/mm_)
Ferritic
Steel
6-9
15-18
Stainless
steel
Austenitic
Martensitic
12-15
9-15
16
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RLL233
Issue 4 Aug 2007
Cutter diameter and speed relationship
High gear.
Low gear.
Selector No
RPM
300
360
430
500
600
650
Cutter Dia.
Selector No
RPM
150
180
215
250
300
330
Cutter Dia.
1
2
3
4
5
6
32
26
22
19
16
14
1
2
3
4
5
6
62
52
46
38
32
30
This data is presented for guidance only, and should be adjusted to suit site and material
conditions.
17
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RLL233
Issue 4 Aug 2007
[14] REPLACEMENT OF MOTOR SUPPLY CABLE.
TO REMOVE OLD CABLE AND CHAIN
Ensure that the machine is disconnected from any source of power. Failure to do so may
result in personal injury.
•
•
•
Remove screws #73 and withdraw the control unit from the housing.
Disconnect the nine-pin cable connector from the control panel
Remove the motor supply cable leads (8 and 9) from the terminal block by unfastening
the screws.
•
•
Release the cable clip inside the housing cavity.
Rotate the capstan to raise the motor & gearbox assembly to the maximum up position
(ensure that cutter retaining screws #11 do not foul arbor support bracket #7).
•
•
•
•
•
•
•
Remove the cable chain anchor screw #68 and release the cable chain #29.
Remove capstan retaining screw #49 and withdraw capstan assembly #55
Withdraw the motor and slide assembly from the housing.
Remove screws #18 and separate motor and slide.
Remove the cable from the cable chain.
Remove screws #67 and cable cover #66.
Release the cable from the cable clip and terminal blocks.
TO REFIT NEW CABLE.
•
•
Reverse the above procedure.
Now test the machine as described below:
Earth Continuity Test
A current of 25A having a no load voltage of 6v is passed between the earth contact of the
mains plug and the frame of the machine. With the standard 3m length of cable the
resistance shall not exceed 0.3 ohms. If this figure is exceeded, a faulty earth connection
has been made. It must be found and rectified.
Insulation Resistance Test
With the magnet switch in the ON position, apply a voltage of 1.5kv between the live
connection on the mains plug and the frame of the machine for a duration of 7 seconds. The
reading obtained should not fall below infinity. Should a fault be indicated it must be found
and rectified.
REPLACEMENT OF MAINS SUPPLY CABLES RD271 and RD272
18
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RLL233
Issue 4 Aug 2007
The replacement is a complete factory produced assembly, and RD272 (230v) is illustrated below.
TO REMOVE OLD CABLE FROM MACHINE
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The machine MUST be disconnected from any source of power supply before attempting to
conduct any maintenance work. Failure to do so may result in personal injury.
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Remove control unit by unfastening screws #73 and lifting the unit clear of the housing.
Remove the 9-pin connector block on the rear of the control unit.
Wires which are fastened into the block and not from the mains cable must not be released.
Unfasten the terminal screws marked L & N and release the mains cable wires.
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The mains supply cable is now only connected to the earth terminal, which is located in the
housing cavity. Release the top nut of the assembly and extract the wire from under the saddle
clamp. All wire connections are now released.
Using a 27mm spanner unfasten the mains cable gland, which screws directly into the housing.
The whole cable assembly comprising of the sleeve, gland and cable will be released.
TO FIT A NEW CABLE
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To fit a new cable, reverse the above procedure.
Now test the machine as described below:
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Conduct an Earth Continuity Test. This is accomplished in the following manner:
A current of 25 amps having a no load voltage of 6V is passed between the earth contact of the
plug (or mains supply earth conductor) and in turn to any accessible metallic part of the machine.
With a standard 3-metre long mains supply cable affixed to the machine the resistance shall not
exceed 0.3 ohms. If this figure is exceeded, a faulty earth connection has been made. It must be
found and rectified.
Insulation Resistance Test
With the magnet switch in the ON position, apply a voltage of 1.5kv between the live
connection on the mains plug and the frame of the machine for a duration of 7 seconds. The
reading obtained should not fall below infinity. Should a fault be indicated it must be found
and rectified.
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