Cobra Electronics CM/200/1 User's Manual
Contents
1. 1 1 14 RLL233 Issue 4 Aug 2007 9 Parts list for CM 200 1 amp CM 200 3 emp Tomponent T Part No ftem Component PartNo tem Component Part No 1 Guard assembly RD25501 6 6 Internal washer RD4069 6 Chain bush RD4521 Guard RD35522 7 Washer RD4070 7 Countersunk set screw RD4018 Pan head screw RD4077 8 Saddle clamp RD4071 8 Chain RD3558 Guard bracket RD3246 9 Pan head screw RD4077 Gib strap assembly RD25510 Spring plunger RD4346 Socket set screw RD4312 1 Gib support strip RD3505 Countersunk screw RD4347 Name plate RD4503 2 Adjustable gib strip RD3504 Bearing bracket assembly RD25503 6 Information plate RD4502 3 Static gib strip RD3503 Arbor bearing RD43301 Conclamp RD472 Oil bottle assembly RD23303 Bearing bracket RD35535 6 Cable clip RD45532 1 Bottle amp bracket RD23317 Motor amp gearbox assembly 110v RD25551 Fixed ratchet wheel RD33338 2 Adjustable ratchet wheel RD33319 Motor amp gearbox assembly 230v RD25553 6 Socket head cap screw RD4414 3 Tension plate RD33320 Motor cable assembly RD25502 6 Pan head screw RD45501 4 Socket head set screw RD4269 Countersunk screw RD4418 Bush RD4079 Control unit assembly 110v RD25511 Cable cover RD33321 Capstan arm assembly RD25504 Control unit assembly 230v RD25513 Socket head cap screw RD4091 1 Capstan arm RD3014 Fascia plate As required Washer RD4092 2 Knob RD43302 1 Shakeproof washer RD402. Item Component Part No Item Component Part No Item Component Part No 1 Motor assembly 110v RD25521 3 7 Speed controller assembly 110v RD23330 7 7 Disk spring RD45506 1 Motor assembly 230v RD25523 3 7 Speed controller assembly 230v RD23343 7 8 Lock nut RD45503 2 Armature assembly 110v RD25531 3 8 Screw RD45501 8 Gearbox assembly RD25506 2 Armature assembly 230v RD25533 3 9 End cap RD35520 5 Gearbox housing assembly RD25515 3 Field coil amp motor housing assembly 110v RD25561 3 10 Screw RD45529 6 Inner gearplate assembly RD25514 3 Field coil amp motor housing assembly 230v RD25563 4 Motor housing assembly RD25512 7 Clutch assembly RD25507 1 1 Socket head cap screw RD45532 4 1 Motor housing RD35516 8 1 Arbor spindle RD35501 1 2 Shakeproof washer RD4092 4 2 Bush RD35532 8 2 Coolant elbow RD43324 1 3 Washer RD4205 4 3 Brush holder RD35517 8 3 Screw RD45510 2 Armature assembly 110v RD25531 5 Gearbox housing assembly RD25515 8 4 Gear selector RD35530 2 Armature assembly 230v RD25533 5 1 Gearbox RD35506 8 5 Bush RD45521 2 1 Bearing RD45517 5 2 Seal kit RD45508 8 6 Circlip RD45513 2 2 Armature 110v RD35521 5 3 Bearing kit arbor spindle RD45511 8 7 Socket set screw RD45524 2 2 Armature 230v RD35523 5 4 Circlip RD45512 8 8 Spring RD45516 2 3 Bearing RD45526 5 5 Bearing kit inter pinion shaft RD45502 8 9 Steel ball RD45515 2 4 Speed sensor RD35515 6 Inner gearpla
3. 49 81 33 87 60 48 80 34 84 61 47 78 35 82 62 46 77 36 80 63 45 76 37 77 64 45 75 38 75 65 44 73 2 3 4 5 55 6 95 7 2 8 96 19 54 2 51 3 23 4 97 5 73 6 51 s 30 8 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 60 90 Cast iron Soft 30 50 Hard alloy 15 21 Malleable 15 30 Steel Mild 460 N mm 24 30 460 770 N mm 15 27 770 1070 N mm 9 15 1070 1230 N mm 6 9 Stainless Ferritic 15 18 steel Austenitic 12 15 Martensitic 9 15 16 RLL233 Cutter diameter and speed relationship Issue 4 Aug 2007 High gear Low gear Selector No RPM Cutter Dia Selector No RPM Cutter Dia l 300 32 l 150 62 2 360 26 2 180 52 3 430 22 3 215 46 4 500 19 4 250 38 5 600 16 5 300 32 6 650 14 6 330 30 This data is presented for guidance only and should be adjusted to suit site and material conditions 17 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 e Remove screws 73 and withdraw the control unit from
4. the housing e 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 e Rotate the capstan to raise the motor amp 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 e Withdraw the motor and slide assembly from the housing e 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 e Reverse the above procedure e 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
5. 69 Slide assembly RD25505 Capstan assembly RD25509 2 Pan head screw RD4077 Slide RD35521 Capstan arm assembly RD25504 14 Mains cable assembly 110v RD271 Key RD35536 2 Capstan hub assembly RD2506 Mains cable assembly 230v RD272 Rack RD4048 3 Pinion RD4049 15 Magnet base assembly RD3557 Socket head cap screw RD4091 4 Pinion shaft collar RD3502 16 Arbor space bracket RD3507 Washer RD4092 5 Pinion bearing RD403 17 Arbor bracket bolt RD4517 Housing sub assembly RD2507 6 Pinion circlip RM22876 18 Shakeproof washer RD4079 Housing RD3500 7 Socket head cap screw RD4098 19 Plain washer RD4078 2 Tension pin RD3026 8 Spring washer RD4207 20 Magnet fixing screw RD4098 Housing assembly RD25508 Cable chain assembly RD2505 Shakeproof washer RD4096 Housing sub assembly RD2507 1 Socket head cap screw RD4414 22 Circlip RD4056 Earth terminal RD3026 2 Shakeproof washer RD4069 23 Button RA354 Aluminum scale RD3027 3 Hex nut RD4250 Compression spring RA355 Countersunk set screw RD4046 4 Washer RD4045 Hex nut RD4068 5 Chain fixing bracket RD3515 N A N R Issue 4 4 2 Was RD3009 Page 11 RLL233 Issue 4 Aug 2007 10 EXPLODED VIEW OF GEARBOX AND MOTOR UNITS Page 12 RLL233 Part list of motor amp gearbox Cobra Issue 4 Aug 2007
6. EAD BEFORE USING THE MACHINE 2 SAFETY PROCEDURES e 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 e 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 e ALWAYS WEAR APPROVED EYE AND EAR PROTRCTION WHEN THE EQUIPMENT IS IN OPERATION Failure to do so may result in personal injury e Disconnect from the power source when changing cutters or working on the machine e When changing cutters or removing swarf ALWAYS wear approved gloves e ALWAYS ENSURE CUTTER RETAINING SCREWS ARE SECURE they sometimes vibrate loose when the machine is in continuous use e Regularly clear the work area and machine of swarf and dirt paying particular attention to the underside of the magnet base e 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 rotatin
7. Magnet 69W Size 180mm long 90mm wide Tractive Force at 20 C with 25mm 1200kgs 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 pe Height maximum extended 550mm Height minimum Width including Hand wheel Length Overall including Guard Nett Weight Maximum hand arm vibration magnitude measured at handle during operation in accordance with ISO5349 0 82 m s _ using a 22mm cutter through 13mm MS plate R 30 holes 2 minute hole 0 29m s A 8 isse BER 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 R
8. REEN start button e ALWAYS switch off the motor by depressing the RED stop button DO NOT switch off the motor by turning the magnet switch to zero e 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 e Always ensure that the slug has been ejected from the previous hole before commencing to cut the next 1 Cut 2 Cut 3 Cut 1 Cut 37 Cut 2 Cut B e Always cut overlapping holes as illustrated above do not use excessive pressure and ensure cutting fluid is reaching teeth of the cutter e Ifthe 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 e 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 e Only use approved cutting fluid Rotabr
9. TM Rotabroach Cobra Magnetic Drilling Machine Models CM 200 1 amp 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 AMEMBER OF THE OSL GROUP OF COMPANIES This machine Serial No is CE approved RLL233 RLL233 Issue 4 Aug 2007 CONTENTS OF THE MANUAL 1 Specification of machine 2 2 General procedures and safety measures 3 Operating instructions 4 4 Extension cable selection 5 5 Mounting of cutters 5 6 Cutters and pilots 6 7 Remedies for hole making problems 7 8 Wiring diagram 9 9 Exploded view and component parts of complete machines 11 10 Exploded view and component parts of gearbox and motor units 12 11 Pipe adapter kit 14 12 Wiring of mains plug 15 13 Cutting Speeds 16 14 Cable replacement 18 UstarGamenswihMasneiebanum ka RA3013 Pilot YESINO RA3030 Pilot d S YP YES NO RA3057 Pilot YES NO RD4088 4mm A F Tee Handled Hexagon Key YES NO RD4152 3mm Hexagon Key YES NO RA3030 YES NO RA3057 YES NO RD4088 YES NO RLL233 Issue 4 Aug 2007 1 ROTABROACH MAGNETIC DRILLING MACHINE MODELS CM 200 1 amp 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 normal full load Electro
10. assed 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 19
11. e 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 Replace Only a few thousandths ejector sleeve wear permissible Too much feed pressure at Light pressure until a groove is cut start of cut The groove then serves as a stabilizer Cutter is worn chipped or Replace or re sharpen Sharpening incorrectly sharpened 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 RLL233 Issue 4 Aug 2007 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 Lubricate gib and or adjust grub lack of lubrication screws Swarf accumulated packed Clear cutter inside cutter Incorrect speed selection Select appropriate speed 4 Excessive cutter Steel swarf or dirt under Remove cutter clean par
12. g 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 e Ifthe 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 e Regularly inspect the machine and check that nuts and screws are tight e 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 e 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 RLL233 Issue 4 Aug 2007 e 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 e Occasionally depress the pilot to ensure cutting fluid is being correctly metered e To start the machine first switch on the magnet by turning the rotary switch to position 1 Then start the motor by depressing the G
13. not fall below infinity Should a fault be indicated it must be found and rectified REPLACEMENT OF MAINS SUPPLY CABLES RD271 and RD272 18 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 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 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 amp N and release the mains cable wires 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 To fit a new cable reverse the above procedure Now test the machine as described below 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 p
14. oach 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
15. 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 Cutter amp Pilot relationship Cutter designation Diameter Pilot type 12 RA3057 RC RCV 13 18 RA359 19 52 RA3047 12 RA3013 RCL RCVL 13 17 RA3030 18 65 RA356 CRWC 18 36 RA3047 12 SRA3057 SRC SRCV 13 52 SRA25 12 SRA3013 SRCL SRCVL 13 65 SRA50 SCRWC 18 36 SRA25 RLL233 Issue 4 Aug 2007 7 REMEDIES FOR HOLE MAKING PROBLEMS 1 Magnetic base Material being cut may be too Attach an additional piece of metal won t hold effectively thin for efficient holding of under work piece where magnet will magnet be located or mechanically clamp magnetic base to work piece Swarf or dirt under magnet Clean magnet Irregularity on magnet face or Us
16. 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 e When cutting the hole DO NOT use excessive pressure but rather let the cutter ease into the cutting surface 60 100mm PIPE DIAMETERS 100mm DIAMETER AND ABOVE Page 14 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 EARTH BLUE NEUTRAL BROWN LIVE 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 e The wire coloured BROWN must be connected to the terminal marked L or coloured RED e 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 RLL233 Issue 4 Aug 2007 13 CUTTING SPEEDS Typical cutting speeds RPM for various materials Cutter Surface speed Cutter Surface speed dia 9 15 30 45 dia 9 15 30 45 45 64 106 212 318 239 47 227 455 6 28 102 171 341 512 30 95 7 50 84 5 31 92 58 49 82 32 90 59
17. t thoroughly breakage cutter and replace Incorrectly re sharpened or Always have a new cutter on hand to worn cutter 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 Refer to instructions and a new cutter cutter for proper tooth geometry Use sufficient steady pressure to Insufficient or spasmodic slow the drill down This will result cutting pressure in optimum cutting speed and chip load RLL233 8 WIRING DIAGRAM oL N oE MAGNET 2 MAGNET 2 MAGNET 1 MAGNET 1 Issue 4 Aug 2007 3 SPEED CONTROLLER MAGNET Ol MOTOR 1 MOTOR 2 CONTROL UNIT CONNECTOR Issue 4 Aug 2007 RLL233 9 EXPLODED VIEW OF COMPLETE MACHINE 11 4 A Y wo
18. te assembly RD25514 8 10 Circlip RD45509 3 Field coil amp motor housing assembly 110v RD25561 6 1 Inner gearplate RD35511 8 11 Spring RD45514 3 Field coil amp motor housing assembly 230v RD25563 6 2 Bearing RD45522 8 12 Gear RD35507 4 Motor housing assembly RD25512 6 3 Bearing RD45507 8 13 Bush RD35514 3 1 Field coil 110v RD35551 7 Clutch assembly RD25507 8 14 Circlip RD45518 3 1 Field coil 230v RD35553 7 1 Interpinion shaft RD35505 8 15 Gear selector ring RD35509 3 2 Screw RD45525 7 2 Washer RD45504 8 16 Snap ring RD45519 3 3 Shakeproof washer RD4092 7 3 Thrust washer RD45505 8 17 Gear RD35512 3 4 Socket head set screw RD45527 7 4 Gear RD35503 8 18 Bush RD35508 3 5 Carbon brush RD35518 7 5 Bush RD35502 8 19 Spring RD45520 3 6 Brush cover RD35519 7 6 Washer RD35504 9 Inner cap RD35513 Page 13 RLL233 Issue 4 Aug 2007 11 PIPE ADAPTOR KIT RD2311 FITTING INSTRUCTIONS e 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 e Locate the machine on the centreline pipe taking care that the magnet is in line with the longitudinal axis of the pipe e 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
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