ROTHENBERGER ROBEND 4000 E Cordless Bending Machine Instruction Manual

ROTHENBERGER ROBEND 4000 E Cordless Bending Machine

EU-DECLARATION OF CONFORMITY

We declare on our sole accountability that this product conforms to the standards and guidelines stated.

ROBEND 4000 E:
2014/30/EU, 2006/42/EG, 2011/65/EU,
EN 62841-1, EN 55014-1, EN 55014-2,
EN IEC 63000

Manufacturer

ppa. Thorsten Bühl
Head of Business Unit
ROTHENBERGER

i.V. Maximilian Gottschalk
Head of New Product
Development

Kelkheim, 01.03.2021

Technical file at:
ROTHENBERGER Werkzeuge GmbH Spessartstraße 2-4 D-65779 Kelkheim/Germany

Charger:
2014/35/EU, 2014/30/EU, 2011/65/EU, EN 60335-1,

• EN 60335-2-29, EN 55014-1, EN 55014-2,
• EN 61000-3-2, EN 61000-3-3, EN 50581

Manufacturer

ppa. Thorsten Bühl
Director Corporate
Technology

i.A. Maximilian Gottschalk
Teamleader Product
Approval & Patents

Kelkheim, 01.09.2018

Technical file at:
ROTHENBERGER Werkzeuge GmbH Spessartstraße 2-4 D-65779 Kelkheim/Germany.

Please read and retain these directions for use. Do not throw them away! The warranty does not cover damage caused by incorrect use of the equipment! Subject to technical modifications!

Markings in this document:

Markings in this document!
This sign warns against the danger of personal injuries.

Caution!
This sign warns against the danger of property damage and damage to the environment.

Call for action

Safety Notes

Intended use

The user bears sole responsibility for any damage caused by improper use. Generally accepted accident prevention regulations and the enclosed safety information must be observed.

ROBEND 4000 E:
The ROBEND 4000 E is suitable for bending copper, stainless steel, and carbon steel pipes. This device may only be used correctly as described. Use only original ROTHENBERGER or CAS (Cordless Alliance System) battery packs and accessories.

Charger and battery:
The chargers are only suitable for charging ROTHENBERGER and CAS (Cordless Alliance System) battery packs.

This tool is not designed for use by persons with physical, sensory or mental disabilities, or with insufficient experience and/or knowledge, unless they are supervised by a person responsible for their safety, or have received instructions on how to use the tool by this person.

Never attempt to charge batteries that are not rechargeable.

The danger of explosion!
Battery packs marked with CAS are 100% compatible with CAS devices (Cordless Alliance System). To select the appropriate device, please contact your ROTHENBERGER dealer. Read the relevant instructions for the devices used.

General Power Tool Safety Warnings

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 electrically operated (corded) power tool or battery-operated (cordless) power tool.

1. Work area safety
   • Keep the work area clean and well-lit. Cluttered and 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 that may ignite dust or fumes.
   • Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
2. Electrical safety
   • 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 the risk of electric shock.
   • 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.
   • Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
   • Do not abuse the cord. Never use the cord for carrying, pulling, or unplugging the power tool. Keep the cord away from heat, oil, sharp edges, and moving parts. Damaged or entangled cords increase the risk of electric shock.
   • When operating a power tool outdoors only, use extension cords suitable for outdoor use. The use of a cord suitable for outdoor use reduces the risk of electric shock.
   • 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.
3. Personal safety
   • 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 momentary lack of attention while operating power tools may result in serious personal injury.
   • Use personal protective equipment. Always wear eye protection. Protective equipment such as dust masks, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
   • Prevent unintentional starting. Ensure the switch is in the off-position before connecting to a 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.
   • 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.
   • Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
   • Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
   • If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. The use of dust collection can reduce dust-related hazards.
   • Do not let familiarity gained from the 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.
4. Power tool use and care
   • Do not force the power tool. Use the correct power tool for your application. The cor-rect power tool will do the job better and safer at the rate for which it was designed.
   • 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.
   • 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.
   • 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.
   • 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 op-eration. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
   • Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
   • Use the power tool, accessories and tool bits etc., in accordance with these instruc-tions, 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.
   • 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.
5. Battery tool use and care
   • Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
   • WARNING! Use power tools only with specifically designated battery packs and respective battery types. Use of any other battery packs may create a risk of explosions, injury and fire.
   • When the battery pack is not in use, keep it away from other metal objects like paper clips, coins, keys, nails, screws, or other small metal objects that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.
   • Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.
   • Do not use a damaged or modified battery. Damaged or modified batteries can behave unexpectedly and lead to fires, explosions or injuries.
   • Do not expose a battery for fire or high temperatures. Fire or temperatures above 130°C (265°F) can cause an explosion.
   • Follow all the instructions for charging and never charge the battery or the cordless tool outside the temperature range specified in the operating instructions. Incorrect charging or charging outside the permitted temperature range can destroy the battery and increase the fire risk.
6. 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.
   • Never service damaged batteries. All maintenance of batteries should only be carried out by the manufacturer or authorised customer service points.

Special safety instructions

ROBEND 4000 E:

• Before starting, the bending area should be clear of any element that may interfere in the bending process.
• Make sure that the on/off switch unlocks automatically when not pressed.
• Make sure that your hands are not in contact with moving parts of the machine during the bending process.
• Remove the battery before carrying out any work on the machine.
• If the device is so badly damaged that electric cables or drive parts are exposed, disconnect the mains plug immediately and contact your service outlet.
• Unauthorised repair work may result in the user suffering major injuries or even death!
• Only start the machine if it is in perfect working order.
• Servicing and repair work may only be carried out by workshops authorised by ROTHEN-BERGER!

Charger and battery:
This charger is not intended for use by children and persons with physical, sensory or mental limitations or a lack of experience or knowledge. This charger can be used by children aged 8 and above and by persons who have physical, sensory or mental limitations or a lack of experience or knowledge if a person responsible for their safety supervises them or has instructed them in the safe operation of the charger and they understand the associated dangers. Otherwise, there is a danger of operating errors and injuries. Supervise children during use, cleaning and maintenance. This will ensure that children do not play with the charger. Do not charge non-rechargeable batteries.

• Danger – electrical voltage!!
• Only use the charger indoors!
• Protect the charger from moisture!
• Never allow children to use the machine. Children should be supervised to ensure that they do not play with the tool.
• Keep children away from the battery charger and the working area!
• Keep your battery charger out of reach of children!
• Pull out the mains plug immediately if the battery charger starts to smoke or flames emerge! Do not insert objects into the ventilation slots on the battery charger – there is a danger of electric shocks and short circuits!
• Do not recharge a fully charged battery pack!
• Protect battery packs from water and moisture!
• Do not expose battery packs to naked flame!
• Do not use faulty or deformed battery packs!
• In areas with high metal dust exposure do not load any battery packs with AIR-COOLED chargers.
• Do not open battery packs!
• Do not touch or short-circuit battery packs!
• Slightly acidic, flammable fluid may leak from defective Li-ion battery packs!
• If battery fluid leaks out and comes into contact with your skin, rinse immediately with plenty of water. If battery fluid leaks out and comes into contact with your eyes, wash them with clean water and seek medical attention immediately!

Transporting li-ion battery packs:
The contained lithium-ion batteries are subject to the Dangerous Goods Legislation requirements. The user can transport the batteries by road without further requirements. When being transported by third parties (e.g.: air transport or forwarding agency), special requirements on packaging and labeling must be observed. For the preparation of the item being shipped, consulting an expert for hazardous material is required. Only send the battery pack if the housing is intact and no fluid is leaking. Remove the battery pack from the machine for sending. Prevent the contacts from short-circuiting (e.g. by protecting them with adhesive tape).

Dispatch batteries only when the housing is undamaged. Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging. Please also observe possibly more detailed national regulations.

Technical Data ROBEND 4000

• Battery voltage …………………………………….1.8V
• Battery capacity (recommendation) ………..≥.. 4.0 Ah
• Dimensions (L x W x H, without battery) …5..78 x 143 x 214 mm
• Weight (without battery) ……………………….1..2,8 kg
• Bending capacity ………………………………..C..opper 12-35 mm/ 1/2 – 1.3/8″ stainless steel/ carbon steel 12-28 mm/ 1/2-1.1/8″
• Bending angle …………………………………….0..º – 180º
• Noise pressure level (LpA) …………………….8..7 dB (A) ¦ KpA 3 dB (A)
• Sound power level (LWA) ………………………1..00 dB (A) ¦ KWA 3 dB (A)
• The noise level during operation can exceed 85 dB (A). Wear hearing protection!
• Measured values determined in accordance with EN 62841-1.
• Vibration total value …………………………….≤.. .5..,.9.. .m…/.s..2. .¦ .K…=.. .1..,.5m/s2

The Vibration Total Value quoted in these instructions and the quoted noise emission values were measured according to standardized measurement procedures and can be used to compare one electric power tool with another. They can also be used to make an initial estimate of the loading.

The quoted vibration and noise emissions can vary during the actual use of the electric power tool dependent on the way in which the electric power tool is used, in particular, what type of workpiece is being processed. Establish additional safety measures to protect the operator which are based upon an estimate of the vibration loading during the actual usage conditions (in doing so taking account of parts of the operating cycle, for example, times in which the electric power tool is switched and those in which it is switched on but not running under load).

Technical Data charger and battery

Battery:

• U = Voltage
• C = Capacity
• W = Weight
• Ic = Charge current
• t = Approx. charging time (90% full)
• Charging voltage…………20,75 V DC
• Charging temperature .. 0° – 50° C, 32° – 122° F Max. discharging
• temperature. ………………5° – 50° C, 41° – 122° F
• Recharge battery pack before first use!

Charger:

• U1 = Input voltage
• f1 = Input frequency
• P1 = Input power
• U2 = Charging voltage
• I2 = Max. charge current
• Nc = No. of battery cells
• W = Weight

Pay attention to the electrical outlet voltage! Check the label on the bottom of the charger!

Function of the Unit

Capacity:
Hard and soft Cu-Al DIN 1786, DIN EN 1057/ 12735-1/ 13348 Øs 12 a 35 mm: 1,2 mm pared, Hard and soft steel DIN 2391, DIN 2393, DIN 2394; Øs 12 a 28 mm x 2,5, Steel DIN 2440 1/4” (14), 3/8” (18), 1/2 “ (22), 3/4 “ (28), INOX AISI 304-316 espesor hasta 1,5 mm Øs 12 a 28 mm.

Overview

1. Battery
2. Reverse lever
3. Handle
4. Bolt housing
5. Tripod
6. Former
7. Former fastening shaft
8. Slide
9. Slide fastening bolt
10. Series bending scale

Changing the battery

Slide the battery in until you hear it lock into place. Remove the battery by pressing down on the lock and then pulling the battery out. Using a battery with at least 4.0Ah is recommended to ensure the optimum processing of pipes with large diameters. Otherwise, the device’s power might be insufficient and the device will switch off during the operating cycle.

Commissioning
The unit provides a device for setting the bending angle automatically from 0º to 180º.

• Loosen the graduated scale surrounding the former shaft and align the desired angle. The machine is now set up and ready for use.

Operation

For all bending applications, carefully follow the steps described!

• Select the tube or pipe to be bent. Choose the relevant bending former and shoe suited to the size of the tube.
• Ensure that the ROBEND 4000 E is set in the start position by starting the motor with the direction lever in the reserve position until it triggers off and moves to the neutral position.
• Place the bending former onto the centrepin. Lay the tube into the bending former and secure it into the hook.
• Ensure that the tubes are fully inserted into the hook and have contact with the whole hook surface.
• Secure the bending shoe with the fastening bolt into the appropriate housing.
• Ensure you are at the correct starting position by checking the “0” mark on the bending former is lined up with the center of the bending shoe.
• To start bending, shift the direction lever to the working position and push the power switch. The bending former will start to rotate.
• Maintain pressure on the switch until your chosen angle of bend (marked on the bending former) lines up with the mark on the bending shoe, and then release the switch.
• The ROBEND® 4000 is equipped with a device that allows you to preset the bending angle between 0 to 180 degrees which is ideal for repeat bends. See “preparation for start-up”.
• Once the been has bent produced and the power switch has been released, shift the direction lever back into the reverse position. Briefly push the power switch to loosen the hold on the tube. Once the tube has released you can remove the fastening bolt, then the bending shoe, and finally take the finished bend out of the bending former.
• In order to make the ROBEND 4000 E ready for the next bending operation, start the motor with the direction lever in the reverse position until it triggers off and moves into the neutral position.

Charger and battery

Overview:

1. Battery pack
2. Sliding seat
3. Operation display
4. Warning display
5. Capacity indicator button
6. Capacity and signal indicator

Start of operation
Before plugging in, check to see that the rated mains voltage and mains frequency, as specified on the rating label, match your power supply!
Devices such as this one, which generates direct current, may have an effect on basic residual-current circuit breakers. Use type F or better, with a release current of max. 30 mA.

Before commissioning the charger, ensure that the air slots are free. The minimum distance to other objects is 5 cm/ 2″!

Self-test:

• Insert mains supply plug.

The warning display (4) and the operating indicator (3) light up one after the other for approx. 1 second and the installed fan runs for approx. 5 seconds.

Battery pack:

• Charge the battery pack before use (1).
• If performance diminishes, recharge the battery pack.
• The ideal storage temperature is between 10°C / 50° F and 30°C / 86° F. The permissible storage temperature is between 0°C and 50°C / 32° – 122° F.
• Li-ion battery packs have a capacity and signal indicator: (6)
• Press the button (5), the LEDs indicate the charge level.
• If one LED is flashing, the battery pack is almost flat and must be recharged.

Handling

Charging battery pack:

• Push the battery pack completely to the stop on the sliding seat (2).

The operating indicator (3) flashes.

Conservation charge:
Once the charging process has finished, the battery charger automatically switches to conservation mode. The battery pack can remain in the battery charger and is therefore always ready for use.

The operating display (3) lights up continuously.

Fault:

• Warning display (4) lights up continuously.

Battery pack is not charged. Temperature too high/ too low. When the temperature of the battery pack is between 0 °C and 50 °C / 32° – 122° F, the charging process begins automatically.

• Warning display (4) flashes.

Battery pack is defective. Remove the battery pack immediately from the charger. The battery pack was not pushed correctly onto the sliding seat (2).

Care and Maintenance

ROBEND 4000 E:
Remove the battery prior to carrying out any work on the machine.

Check that the machine switch unblocks automatically when finger pressure is released. In case of any anomaly, replace it immediately with a new one. Change grease every 500 operating hours. After dismounting the machine, oil all mechanisms to eliminate old grease. Remove parts with dry compressed air and apply new grease with clean hands. Do not use any dissolvents. Approximately 300 hrs. of grease is needed for correct lubrication. An excessive amount of grease is not recommended as it can increase the temperature of the machine. Grease type: LGMT2 by SKF or similar. We recommend that this operation be carried out by an authorized after-sales service.

Machine maintenance and repair should be done by a specialist.

Charger:
Repairs to the charger must only be carried out by qualified electricians.

If the mains connection cable of this tool is damaged, in order to prevent endangering personnel and property it must be replaced by the manufacturer, or the Customer Service of the manufacturer, or a similarly qualified person.

Troubleshooting

The bending former stops rotation during bending, while the motor is still run- ning| The direction lever is not in the right position| There is a transmission problem – contact your technical service centre
Bends are not round/circular| Bending former and/or shoe are not suited to the tube size.

Bending former and/or shoe are worn out.

Tube quality is suspect

|
The ROBEND 4000 E does not start| Check the wiring in the plug.| Carbon brushes may be worn out and need replacing
Pre-set trigger does not function| Screws are not tightened properly|

Accessories

You can find suitable accessories in the main catalog or at www.rothenberger.com.

Customer service

The ROTHENBERGER service locations are available to help you (see a listing in catalog or online) and replacement parts and services are also available through these same service locations. Order your accessories and spare parts from your specialist retailer or using RO SERVICE+ online: ℡ + 49 (0) 61 95/ 800 8200 + 49 (0) 61 95/ 800 7491 * service@rothenberger.com – www.rothenberger.com.

Disposal
The components of the unit are recyclable materials and should be put into recycling. For this purpose registered and certified recycling companies are available. For environmentally friendly disposal of non-recyclable parts (e.g. electronic waste) please contact your local waste disposal authority.
Old batteries can be taken to your specialist dealer who will dispose of them in conformity with environmental regulations.

For EU countries only:
Do not dispose of electric tools with domestic waste. In accordance with European Directive 2012/19/EU on waste electrical and electronic equipment and its implementation as national law, electric tools that are no longer serviceable must be collected separately and utilised for environmentally compatible recycling.

ROTHENBERGER Werkzeuge GmbH
Industriestraße 7 D-65779 Kelkheim / Germany
Telefon +49 6195 / 800 – 0
Telefax +49 6195 / 800 – 3500
info@rothenberger.com.
rothenberger.com.

References

• ROTHENBERGER USA
• ROTHENBERGER USA

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