REMS 2000 Electric Soldering Unit Instruction Manual

REMS Tornado 2000 / 2010 / 2020
REMS Magnum 2000 / 2010 / 2020
REMS Magnum 3000 / 3010 / 3020
REMS Magnum 4000 / 4010 / 4020

Instruction Manual

2000 Electric Soldering Unit

REMS GmbH & Co KG
Maschinen- und Werkzeugfabrik
Stuttgarter Straße 83
71332 Waiblingen
Deutschland
Telefon +49 7151 1707-0
Telefax +49 7151 1707-110
www.rems.de

REMS Tornado 2000 / 2010 / 2020

REMS Magnum 2000 / 2010 / 2020 / 3000 / 3010 / 3020 / 4000 / 4010 / 4020
Translation of the Original Instruction Manual
REMS Tornado 2000 / 2010 / 2020REMS Tornado 2000 / 2010 / 2020

1 Wing screw
2 Tool holder
3 Guiding arm front
4 Guiding arm back
5 Pressing lever
6 Clamping ring
7 Handle
8 Die head
9 Length stop
10 Closing and opening lever
11 Clamping lever
12 Adjusting disk| 13 Knob/recessed grip
14 Die holder
15 Pipe cutter
16 Deburer
17 Pouring spout
18 Switch right-left
19 Chuck
21 Foot switch
22 Emergency switch
23 Thermal protection switch
24 Guiding bolt
---|---

REMS Magnum 2000 / 2010 / 2020 / 3000 / 3010 / 3020 / 4000 / 4010 / 4020

1 Quick action hammer chuck
2 Guide chuck
3 Switch right-left
4 Foot switch
5 Emergency stop switch
6 Thermal protection switch
7 Tool holder
8 Pressing lever
9 Handle
10 Clamping ring with wing nut
11 Wing screw
12 Die head
13 Length stop| 14 Closing and opening lever
15 Clamping lever
16 Adjusting disk
17 Die holder
18 Pipe cutter
19 Deburrer
20 Oil tray
21 Chip tray
22 Clamping ring
23 Chuck jaw carrier
24 Chuck jaws
25 Screw plug
---|---

General power tool safety warnings

WARNING
Read all safety warnings, instructions, illustrations and specifi cations 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.

1. Work area safety
   a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   b) 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.
   c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2. 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 movingparts.
   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.

3. 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 infl uence 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.
   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 fi nger 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.

4. 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.

5. Service
   a) Have your power tool serviced by a qualifi ed repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Threading Machine Safety Warnings
WARNIN
Read all safety warnings, instructions, illustrations and specifi cations provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fi re and/or serious injury.

Save all warnings and instructions for future reference.
Work area safety

• Keep floor dry and free of slippery materials such as oil. Slippery floors invite accidents.
• Restrict access or barricade the area when work piece extends beyond machine to provide a minimum of one metre clearance from the work piece.
  Restricting access or barricading the work area around the work piece will reduce the risk of entanglement.

Electrical safety

• Keep all electrical connections dry and away from the floor. Do not touch plugs or the machine with wet hands. These safety precautions reduce the risk of electric shock.

Personal safety

• Do not wear gloves or loose clothing when operating machine. Keep sleeves and jackets buttoned. Do not reach across the machine or pipe. Clothing can be caught by the pipe or machine resulting in entanglement.

Machine safety

• Do not use the machine if it is damaged. There is a danger of accident.
• Follow instructions on proper use of this machine. Do not use for other purposes such as drilling holes or turning winches. Other uses or modifying this power drive for other applications may increase the risk of serious injury.
• Secure machine to bench or stand. Support long heavy pipe with pipe supports. This practice will prevent machine tipping.
• While operating the machine, stand on the side where the FORWARD/ REVERSE switch is located. Operating the machine from this side eliminates the need to reach over the machine.
• Keep hands away from rotating pipes or fi ttings. Switch off the machine before cleaning pipe threads or screwing on fi ttings. Let the machine come to a complete standstill before touching the pipe. This procedure reduces the possibility of getting trapped by rotating parts.
• Do not use the machine for screwing on or unscrewing fi ttings; it is not intended for this purpose. Such use could lead to trapping, entanglement and loss of control.
• Keep covers in place. Do not operate the machine with covers removed. Exposing moving parts increases the probability of entanglement.

Footswitch safety

• Do not use this machine if the footswitch is broken or missing. Footswitch is a safety device that provides better control by letting you shut off the motor in various emergency situations by removing your foot from the switch. For example:  if clothing should become caught in the machine, the high torque will continue pulling you into the machine. The clothing itself can bind around your arm or other body parts with enough force to crush or break bones.

Additional Safety Instructions for Thread Cutting Machines

• Only connect the machine of protection class I to a socket/extension lead with a functioning protective contact. There is a danger of electric shock.

• Check the power cable of the machine and extension leads regularly for damage. Have these renewed by qualifi ed experts or an authorised REMS customer service workshop in case of damage.

• The machine is operated by a safety foot switch with emergency stop in inching mode. If you cannot see the danger area constituted by the revolving workpiece from the operating point, set up protective measures, e.g. cordons.
  There is a risk of injury.

• Only use the machine for the intended purpose described in 1. Technical Data. Work such as roping, assembling and disassembling, thread cutting with manual die stocks, work with manual pipe cutters as well as holding workpieces by hand instead of with material supports are prohibited when the machine is running. There is a risk of injury.

• If the risk of bending and uncontrolled lashing of the workpieces is to be expected (depending on the length and cross section of the material and the speed of rotation) or the machine is not standing stably enough (e.g. when using the REMS 4″ automatic die head), suffi cient numbers of height adjustable material supports REMS Herkules 3B, REMS Herkules XL 12″ (accessory, Art. No. 120120, 120125) must be used. There is a risk of injury if you fail to do so.

• Never reach into the revolving clamping or guide chuck. There is a risk of injury.

• Clamp short pipe sections only with REMS Nippelspanner or REMS Nippelfi x. Machine and/or tools can be damaged.

• Thread cutting materials in spray cans (REMS Spezial, REMS Sanitol) contains environmentally friendly but highly infl ammable propellant gas (butane). Aerosol cans are pressurised; do not open by force. Protect them against direct sunlight and  temperatures above 50°C. The aerosol cans can burst, risk of injury.

• Avoid intensive skin contact with the coolant-lubricants. These have a degreasing effect. A skin protector with a greasing effect must be applied.

• Never let the machine operate unattended. Switch off the machine during longer work breaks, pull out the mains plug. Electrical devices can cause hazards which lead to material damage or injury when left unattended.

• Only allow trained persons to use the machine. Apprentices may only use the machine when they are over 16, when this is necessary for their training and when they are supervised by a trained operative.

• Children and persons who, due to their physical, sensory or mental abilities or lack of experience and knowledge are unable to operate the machine safely may not use this machine without supervision or instruction by a responsible person. Otherwise there is a risk of operating errors and injuries.

• Check the power cable of the electric al device and extension leads regularly for damage. Have these renewed by qualifi ed experts or an authorised REMS customer service workshop in case of damage.

• Only use approved and appropriately marked extension leads with a sufficient cable cross-section. Use extension leads with a cable cross-section of at least 2.5 mm².

NOTIC

• Do not dispose of thread-cutting material undiluted in the drain system, ground water or ground. Unused thread-cutting material should be handed in to responsible disposal companies. Waste code for thread-cutting materials containing mineral oil (REMS Spezial) 120106, for synthetic materials (REMS Sanitol) 120110. Waste code for thread cutting materials containing mineral oils (REMS Spezial) and synthetic thread cutting materials (REMS Sanitol) in spray cans 150104. Observe the national regulations.

Explanation of symbols

WARNING| Danger with a medium degree of risk which could result in death or severe injury (irreversible) if not heeded.
---|---
CAUTION| Danger with a low degree of risk which could result in minor injury (reversible) if not heeded.
NOTICE| Material damage, no safety note! No danger of injury.
| Read the operating manual before starting
| Use eye protection
| Use ear protection
| Power tool complies with protection class I
| Power tool complies with protection class II
| Environmentally friendly disposal
****| CE conformity mark

Technical Data

Use for the intended purpose
WARNING

Use REMS Tornado and REMS Magnum (type 340001, 340002, 340003, 340004, 340005, 340006, 380010, 380011, 380012) thread cutting machines for the intended purpose of thread cutting, cutting off, removing burr, cutting nipples and roller grooves.
All other uses are not for the intended purpose and are therefore prohibited.

1.1. Scope of Supply
REMS Tornado: Thread cutting machine, tool set (¹/16) ⅛ – 2″, REMS dies R ½ – ¾” and R 1 – 2″, height-adjustable material rest, oil tray, chip tray, operating instructions.
REMS Magnum up to 2″: Thread cutting machine, tool set (¹/16) ⅛ – 2″, REMS dies R ½ – ¾” and R 1 – 2″, oil tray, chip tray, operating instructions.
REMS Magnum up to 3″ (R 2½ – 3″): Thread cutting machine, tool set 2½ – 3″, REMS dies R 2½ – 3″, oil tray, chip tray, operating instructions.
REMS Magnum up to 4″ (R 2½ – 4″): Thread cutting machine, tool set 2½ – 4″, REMS dies R 2½ – 4″, oil tray, chip tray, operating instructions.
Equipped if necessary with additional tool set (¹/16) ⅛ – 2″ with REMS dies R ½ – ¾” and R 1 – 2″.

1.2. Article Numbers

| REMS Tornado 2000 REMS Tornado 2010 REMS Tornado 2020| REMS Magnum 2000 REMS Magnum 2010 REMS Magnum 2020| REMS Magnum 3000 REMS Magnum 3010 REMS Magnum 3020| REMS Magnum 4000
REMS Magnum 4010
REMS Magnum 4020
---|---|---|---|---
Subframe Wheel set with material rest Subframe, mobile and folding Subframe, mobile, with material rest Dies Universal automatic
die head ¹/16 – 2″ Universal automatic
die head 2½ – 3″ Universal automatic
die head 2½ – 4″ Tool set ¹/16 – 2″ REMS 4″ automatic die head
REMS cutting wheel St ⅛ – 4″, S 8
REMS cutting wheel St 1 – 4″, S 12
Thread-cutting materials
Nippelhalter
REMS Herkules 3B
REMS Herkules Y
REMS Herkules XL 12″
REMS roller groove device
Clamping sleeve
Changeover valve
REMS CleanM, Machine cleaner ,| 344105
344120
344150
344100
see REMS catalogue
341000
341000
370010 (R 2½ – 4″)
370011 (NPT 2½ – 4″)
341614
see REMS catalogue
see REMS catalogue
120120
120130
120125
347000
343001
140119| 344105
344120
344150
344100
see REMS catalogue
341000
340100
370010 (R 2½ – 4″)
370011 (NPT 2½ – 4″)
341614
see REMS catalogue
see REMS catalogue
120120
120130
120125
347000
343001
342080
140119| 344105
344120
344150
344100
see REMS catalogue
341000
381050
381000
340100
341614
381622
see REMS catalogue
see REMS catalogue
120120
120130
120125
347000
343001
342080
140119| 344105
344120
344150
344100
see REMS catalogue
341000
381000
341000
341614
381622
see REMS catalogue
see REMS catalogue
120120
120130
120125
347000
343001
342080
140119

1.3. Applications

1.3.1. Thread diameter
Pipe (also plastic-coated) Bolt| (¹/16) ⅛ – 2″, 16 – 63 mm (6) 10 – 60 mm, ¼ – 2″| (¹/16) ⅛ – 2″, 16 – 63 mm (6) 8 – 60 mm, ¼ – 2″| (¹/16) ½ – 3″, 16 – 63 mm (6) 20 – 60 mm, ½ – 2″| (¹/16) ½ – 4″, 16 – 63 mm
(6) 18 – 60 mm, ½ – 2″
---|---|---|---|---
1.3.2. Thread types
Pipe thread,
tapered right-handed Pipe thread,
cylindrical right-handed
Steel armoured thread
Bolt thread| R (ISO 7-1, EN 10226, DIN 2999, BSPT), NPT
G (EN ISO 228-1, DIN 259, BSPP), NPSM
Pg (DIN 40430), IEC
M (ISO 261, DIN 13), UNC, BSW
---|---
1.3.3. Thread length
Pipe thread, tapered| standard length| standard length| standard length| standard length
---|---|---|---|---
Pipe thread, cylindrical
Bolt thread| 165 mm, with
re-tighten
unlimited| 150 mm, with
re-tighten
unlimited| 150 mm, with
re-tighten
unlimited| 150 mm, with
re-tighten
unlimited
1.3.4. Cut off pipe| ⅛ – 2″| ⅛ – 2″| ¼ – 4″| ¼ – 4″
1.3.5. Deburr inside of pipe| ¼ – 2″| ¼ – 2″| ¼ – 4″| ¼ – 4″
1.3.6. Nipple and double nipple with
REMS Nippelspanner (inside clamping) with REMS Nippelfi x
(automatic inside clamping)| ⅜ – 2″
½ – 4″| ⅜ – 2″
½ – 4″| ⅜ – 2″
½ – 4″| ⅜ – 2″
½ – 4″
1.3.7. REMS roller groove device
REMS Tornado/Magnum version L-T REMS Tornado/Magnum version T| DN 25 – 200, 1 – 8″ DN 25 – 200, 1 – 8″ s ≤ 7.2 mm| DN 25 – 300, 1 – 12″ DN 25 – 200, 1 – 8″ s ≤ 7.2 mm| DN 25 – 300, 1 – 12″ DN 25 – 200, 1 – 8″ s ≤ 7.2 mm| DN 25 – 300, 1 – 12″
DN 25 – 200, 1 – 8″
s ≤ 7.2 mm

1.3.8. REMS 4″ automatic die head for all REMS Tornado and REMS Magnum
2000/2010/2020 types
2½ – 4″ 2½ – 4″
Operating temperature range
REMS Tornado, REMS Magnum all types –7 °C – +50 °C (19 °F – 122 °F)
1.4. Speeds of the Work Spindles

REMS Tornado 2000
REMS Magnum 2000
REMS Magnum 3000
REMS Magnum 4000
automatic, continuous speed regulation
REMS Tornado 2010 / 2020
REMS Magnum 2010 / 2020
REMS Magnum 3010 / 3020
REMS Magnum 4010 / 4020| 53 rpm
53 rpm
23 rpm
23 rpm
52 – 26 rpm
52 – 26 rpm
20 – 10 rpm
20 – 10 rpm
---|---

also under full load For high stress and poor electricity conditions for larger threads Tornado 26 rpm or Magnum 10 rpm

1.5. Electrical Data

REMS Tornado 2000,
REMS Magnum 2000 / 3000 / 4000| 230 V ~; 50 – 60 Hz; 1,700 W consumption, 1,200 W output; 8.3 A;
Fuse (mains) 16 A (B). Periodic duty S3 25% AB 2,5/7,5 min. protection class ll.
110 V ~; 50 – 60 Hz; 1,700 W consumption, 1,200 W output; 16.5 A;
Fuse (mains) 30 A (B). Periodic duty S3 25% AB 2,5/7,5 min. protection class ll.
---|---
REMS Tornado 2010,
REMS Magnum 2010 / 3010 / 4010| 230 V ~; 50 Hz; 2,100 W consumption, 1,400 W output; 10 A;
Fuse (mains) 10 A (B). Periodic duty S3 70% AB 7/3 min. protection class l.
REMS Tornado 2020,
REMS Magnum 2020 / 3020 / 4020| 400 V; 3~; 50 Hz; 2,000 W consumption, 1,500 W output; 5 A;
Fuse (mains) 10 A (B). Periodic duty S3 70% AB 7/3 min. protection class l.

1.6. Dimensions (L × W × H)

REMS Tornado 2000
REMS Tornado 2010 / 2020
REMS Magnum 2000
REMS Magnum 2010 / 2020
REMS Magnum 3000
REMS Magnum 3010 / 3020
REMS Magnum 4000
REMS Magnum 4010 / 4020| 730 × 435 × 280 mm
730 × 435 × 280 mm
870 × 580 × 495 mm
825 × 580 × 495 mm
915 × 580 × 495 mm
870 × 580 × 495 mm
915 × 580 × 495 mm
870 × 580 × 495 mm
---|---

1.7. Weight in kg

| REMS Tornado 2000
REMS Tornado 2010
REMS Tornado 2020| REMS Magnum 2000
REMS Magnum 2010
REMS Magnum 2020| REMS Magnum 3000
REMS Magnum 3010
REMS Magnum 3020| REMS Magnum 4000
REMS Magnum 4010
REMS Magnum 4020
---|---|---|---|---
REMS Tornado 2000 / T
REMS Tornado 2010 / T
REMS Tornado 2020 / T
REMS Magnum 2000 LT / T
REMS Magnum 2010 LT / T
REMS Magnum 2020 LT / T
REMS Magnum 3000 LT / T
REMS Magnum 3010 LT / T
REMS Magnum 3020 LT / T
REMS Magnum 4000 LT / T
REMS Magnum 4010 LT / T
REMS Magnum 4020 LT / T
Subframe Subframe, mobile Subframe, mobile and folding| Machine without tools set
41.2 / 59.8
53.9 / 72.5
52.8 / 71.4
44.4 / 59.0
57.1 / 71.7
56.0 / 70.6
59.4 / 74.0
57.1 / 86.7
71.0 / 85.6
59.4 / 74.0
57.1 / 86.7
71.0 / 85.6
12.8
22.5
23.6| Tool set ½ – 2″ (with REMS dies, set)
13.8
13.8
13.8
13.8
13.8
13.8
13.8
13.8
13.8
13.8
13.8
13.8| Tool set 2½ – 3″ (with REMS dies, set)
–
–
–
–
–
–
22.7
22.7
22.7
–
–
–| Tool set 2½ – 4″
(with REMS dies, set)
–
–
–
–
–
–
–
–
–
24.8
24.8
24.8

1.8. Noise information

Workplace-related emissions value
REMS Tornado 2000,
REMS Magnum 2000 / 3000 / 4000
REMS Tornado 2010,
REMS Magnum 2010 / 3010 / 4010
REMS Tornado 2020
REMS Magnum 2020 / 3020 / 4020| Lpa + Lwa 83 dB (A) K=3dB
Lpa + Lwa 75 dB (A) K=3 cB
Lpa + Lwa 72 dB (A) K=3dB
Lpa + Lwa 74 0B (A) K=30B
---|---

1.9. Vibrations (all types)
Weighted rms value of acceleration < 2.5 m/s² K = 1.5 m/s²
The indicated weighted effective value of acceleration has been measured against standard test procedures and can be used by way of comparison with another device. The indicated weighted effective value of acceleration can also be used as a preliminary evaluation of the exposure.

CAUTION

The indicated weighted effective value of acceleration can differ during operation from the indicated value, dependent on the manner in which the device is used.
Dependent upon the actual conditions of use (periodic duty) it may be necessary to establish safety precautions for the protection of the operator.

Start-up

CAUTION
Observe and follow the national rules and regulations for manual handling of load weights.

2.1. Installing REMS Tornado 2000, 2010, 2020 (Fig.1 – 3)
Undo the wing nut (1). Remove the tool carrier (2). Place the machine vertically on both guide arms (3 + 4) and hold tight, insert the 3 tubular legs into the gear housing until they snap in (Fig. 1). Hold the machine by the guide arms (not by the tubular legs) and place on the tubular legs (Fig. 2). Fix the included heightadjustable material rest to the gear housing from below on the motor side.The machine can also be placed on and screwed to a workbench. There are 3 threaded holes on the bottom of the machine for this. Drill 3 holes (drill Ø 12 mm) in the workbench using the template included in the operating instructions. The machine is then bolted with 2 M 10 bolts from underneath. The enclosed height-adjustable material rest cannot be used. Use the REMS Herkules 3B, REMS Herkules Y or REMS Herkules XL 12″ material rest (accessory). Push the tool carrier into the guide arms. Push the pressing lever (5) from the rear through the loop on the tool carrier and the clamping ring (6) onto the rear guide arm so that the wing nut is facing the rear and the ring groove stays free. Push the handle (7) onto the pressing lever. Hang the oil tray in the two screws on the bottom of the gear housing and push to the right into the slits. Hang the oil tray in the ring groove on the rear guide arm (4). Push on the clamping ring (6) until it is touching the suspension of the oil tray and clamp it tight. Hang the hose with suction fi lter into the oil tray and push the other end of the hose onto the nipple on the back of the tool carrier.
Fill in 2 litres of thread cutting material. Insert the chip tray from the rear.

NOTICE
Never operate the machine without thread cutting material.
Insert the guide bolt of the die head (8) into the hole of the tool carrier and push on the die head with axial pressure on the guide pin and swivelling movements as far as it will go.
Hang the foot switch on the screw on the back of the gear housing for better transport (Fig. 3).
Installing REMS Magnum 2000 T, 2010 T, 2020 T, 3000 T, 3010 T, 3020 T, 4000 T, 4010 T, 4020 T (Fig. 8)
Remove both U-rails from the machine. Fix the machine to the oil tray. Push the tool carrier into the guide arms. Push the pressing lever (8) from the rear through the loop on the tool carrier and the clamping ring (10) onto the rear guide arm so that the wing nut is facing the rear and the ring groove stays free.
Feed the hose with suction fi lter through the hole in the oil tray from the inside and connect it to the coolant-lubricant pump. Push the other end of the hose onto the nipple on the back of the tool carrier. Push the handle (9) onto the pressing lever. Fix the machine to a workbench or subframe (accessory) with the 3 screws provided. The machine can be lifted respectively at the front by the guide arms and at the rear by a pipe clamped into a clamping and guide chuck for transport. For transporting on the subframe, pipe sections Ø ¾” with a length of approx. 60 cm are pushed into the eyes on the subframe and fixed with the wing nuts. If the machine is not to be transported, the two wheels can be removed from the subframe.

Fill in 5 litres of thread cutting material. Insert chip tray.

NOTICE
Never operate the machine without thread cutting material.
Insert the guide bolt of the die head (12) into the hole of the tool carrier and push on the die head with axial pressure on the guide pin and swivelling movements as far as it will go.

2.2. Installing REMS Tornado 2000 T, 2010 T, 2020 T (Fig. 7 + 8)
Fix the console to the oil tray. Fix the machine and holder of the height- adjustable material rest to the console. Push the tool carrier into the guide arms. Push the pressing lever (5) from the rear through the loop on the tool carrier and the clamping ring (6) onto the rear guide arm so that the wing nut is facing the rear and the ring groove stays free. Feed the hose with suction fi lter through the hole in the oil tray from the inside and connect it to the coolant-lubricant pump. Push the other end of the hose onto the nipple on the back of the tool carrier. Push the handle (7) onto the pressing lever. Fix the machine to a workbench or subframe (accessory) with the 3 screws provided. The machine can be lifted respectively at the front by the guide arms and at the rear by the motor or by the holder of the material rest. For transporting on the subframe, pipe sections Ø ¾” with a length of approx. 60 cm are pushed into the eyes on the subframe and fi xed with the wing nuts. If the machine is not to be transported, the two wheels can be  removed from the subframe.
Fill in 5 litres of thread cutting material. Insert chip tray.

NOTICE
Never operate the machine without thread cutting material.
Insert the guide bolt of the die head (8) into the hole of the tool carrier and push on the die head with axial pressure on the guide pin and swivelling movements as far as it will go.

Installing REMS Magnum 2000 L-T, 2010 L-T, 2020 L-T, 3000 L-T, 3010 L-T, 3020 L-T, 4000 L-T, 4010 L-T, 4020 L-T (Fig. 8)
Fix the machine to a workbench or subframe (accessory) with the 4 screws provided. The machine can be lifted respectively at the front by the guide arms and at the rear by a pipe clamped into a clamping and guide chuck for transport.
Push the tool carrier into the guide arms. Push the pressing lever (8) from the rear through the loop on the tool carrier and the clamping ring (10) onto the rear guide arm so that the wing nut is facing the rear and the ring groove stays free. Push the handle (9) onto the pressing lever. Hang the oil tray in the two screws on the gear housing and push to the right into the slits. Hang the oil tray in the ring groove on the rear guide arm. Push on the clamping ring (10) until it is touching the suspension of the oil tray and clamp it tight. Hang the hose with suction filter into the oil tray and push the other end of the hose onto the nipple on the back of the tool carrier.
Fill in 2 litres of thread cutting material. Insert the chip tray from the rear.

NOTICE
Never operate the machine without thread cutting material.
Insert the guide bolt of the die head (12) into the hole of the tool carrier and push on the die head with axial pressure on the guide pin and swivelling movements as far as it will go.

2.3. Electrical connection

WARNING
Caution: Mains voltage present! Before connecting the thread cutting machine, check whether the voltage given on the rating plate corresponds to the mains voltage. Only connect the thread cutting machine of protection class I to a socket/extension lead with a functioning protective contact. There is a danger of electric shock. On building sites, in a wet environment, indoors and outdoors or under similar installation conditions, only operate the thread cutting machine on the mains with a fault current protection switch (FI switch) which interrupts the power supply as soon as the leakage current to earth exceeds 30 mA for 200 ms.
The thread cutting machine is switched on and off with the foot switch (21, REMS Tornado / 4, REMS Magnum). The switch (18, REMS Tornado / 3, REMS Magnum) serves to pre-select the direction of rotation or speed. The machine can only be switched on when the emergency off button (22, REMS Tornado / 5, REMS Magnum) is unlocked and the thermal protection switch (23, REMS Tornado / 6, REMS Magnum) on the foot switch is pressed. If the machine is connected directly to mains (without a plug device), a 16 A circuit breaker must be installed.

2.4. Thread-cutting Materials
Safety data sheets see www.rems.de → Downloads → Safety data sheets.
Only use REMS thread cutting materials. They ensure perfect cutting results, long life of the dies and considerably relieve stress on the tools.

NOTICE

REMS Spezial: High-alloy mineral oil-based thread-cutting material. For all materials: steel, stainless steel, non-ferrous metals, plastics. Can be washed out with water, tested by experts. Mineral oil-based thread cutting materials are not approved for drinking water pipes in different countries, e.g. Germany, Austria and Switzerland. Mineral oil-free REMS Sanitol must be used in this case. Observe the national regulations.
REMS Sanitol: Mineral oil-free, synthetic thread-cutting material for drinking water pipes. Completely soluble in water. According to regulations. In Germany DVGW test no. DW-0201AS2032, Austria ÖVGW test no. W 1.303, Switzerland SVGW test no. 7808-649. Viscosity at –10°C: ≤ 250 mPa s (cP). Pumpable up to –28°C. Easy to use. Dyed red for checking washout. Observe the national regulations.
Both thread cutting materials are available in aerosol cans, spray bottles, canisters and barrels.

NOTICE
All thread cutting materials may only be used in undiluted form!

2.5. Material Support
CAUTION
Pipes and bars longer than 2 m must be supported additionally by at least one height-adjustable REMS Herkules 3B, REMS Herkules XL 12″ material rest.
This has steel balls for easy movement of the pipes and bars in all directions without the material support tipping over.

2.6. REMS 4″ Automatic Die Head
When using the REMS 4″ automatic die head, the operating instructions included with the REMS 4″ automatic die head must be observed.

2.7. Subframe, mobile and folding (accessory)
CAUTION
The folded subframe, mobile and folding, quickly moves up automatically without mounted thread cutting machine after releasing. Therefore hold down the subframe by the handle when releasing and hold with both handles when moving up.
To move up with the thread cutting machine mounted, hold the subframe with one hand on the handle, put one foot on the cross member and release both locking pins by turning the lever. Then hold the subframe with both hands and move to working height until the two locking pins snap in. Proceed in the reverse order to fold up. Drain the thread-cutting material from the oil tray or remove the oil tray before unfolding or folding up.

Operation

Use eye protection
Use ear protection

3.1. Tools
The die head (8, REMS Tornado / 12, REMS Magnum) is respectively a universal die head, i.e. for the above mentioned ranges, divided into 2 tool sets, only one die head is required. To cut tapered pipe threads, the length stop (9, REMS Tornado / 13, REMS Magnum) with the closing and opening lever (10, REMS Tornado / 14, REMS Magnum) must be in the same direction. The die head then opens automatically on reaching the respective standard thread length. The length stop (9, REMS Tornado / 13, REMS Magnum) is folded away to be able to cut cylindrical long threads and bolt threads.

Changing the REMS dies
The REMS dies can be inserted or changed both with mounted and removed die head (e.g. on the workbench). Release the clamping lever (11, REMS Tornado / 15, REMS Magnum) to do this, do not unscrew. Push the adjusting disc (12, REMS Tornado / 16, REMS Magnum) on the handle away from the clamping lever into the end position. The REMS dies are removed and inserted in this position. Make sure that the thread size specifi ed on the rear of the REMS dies corresponds to the thread size to be cut. Also  make sure that the numbers also specifi ed on the back of the REMS dies match those on the die holder (14, REMS Tornado / 17, REMS Magnum).
Push the REMS dies into the die head until the ball in the slit of the die holder snaps in. When all REMS dies are inserted, the desired thread size is set by moving the adjusting disc. Always set bolt threads to “Bolt”. Clamp the adjusting disc with the clamping lever. Close the cutting head. Press the closing and opening lever (10, REMS Tornado / 14, REMS Magnum) fi rmly down to the right to do this. The die head opens either automatically (for tapered pipe threads) or at any time manually by exerting slight pressure on the left of the closing and opening lever.
If the holding force of the clamping lever (11, REMS Tornado / 15, REMS Magnum) is not suffi cient for the die head 2½ – 3″ and 2½ – 4″ due to increased cutting force (e.g. blunt REMS dies), i.e. the die head opens under cutting pressure, the cylinder head screw on the side opposite the clamping lever (11, REMS Tornado / 15, REMS Magnum) must be tightened additionally.
The pipe cutter (15, REMS Tornado / 18, REMS Magnum) is for cutting ⅛ – 2″ or 2½ – 4″ pipes.
The pipe inside deburrer (16, REMS Tornado / 19, REMS Magnum) is used for ¼ – 2″ or 2½ – 4″ pipes. Secure the quill by snapping into the deburring arm; front or rear, depending on the length of the pipe.

3.2. Chuck
A clamping sleeve (Art. No. 343001) adapted to the diameter is required for REMS Magnum up to 2″ and REMS Tornado for clamping diameters < 8 mm, for REMS Magnum up to 4″ for clamping diameters < 20 mm. The desired clamping diameter must be specified when ordering the clamping sleeve.

3.2.1. Chuck REMS Tornado (19)
The self-centring dies open and close automatically by turning the switch to the left or right (18) and actuating the foot switch (21). When changing the front and rear dies, please make sure that the individual dies are inserted as shown in Fig. 4 and 5 because otherwise damage will be caused. The machine may never be switched on before all dies and both chuck covers are fi tted.

3.2.2. Quick Action Hammer Chuck (1), Guide Chuck (2) REMS Magnum
The quick action hammer chuck (1) with large clamping ring and moving dies inserted into the die carriers ensures centred and safe clamping with the least force. As soon as the material protrudes from the guide chuck, this must be closed.
To change the dies (24), close the clamping ring (22) up to approx. 30 mm clamping diameter. Remove screws of the dies (24). Push out the dies to the back with a suitable tool (screwdriver). Push the new dies with inserted screw into the die carriers from the front.

3.3. Work Procedure
Remove blockages of chips and fragments of the workpiece before starting work.

NOTICE
Switch off the thread cutting machine when the tool set approaches the machine housing.

3.3.1. REMS Tornado
Swing out tools and move the tool carrier to the right end position with the pressing lever (5). Insert the material so that it protrudes approx. 10 cm from the chuck (19). Swing down and close the dies head (8). Switch the switch (18) to position 1, actuate the foot switch (21). Now the material is clamped automatically.

CAUTION
Never reach into the revolving clamping or guide chuck. There is a risk of injury.
With types 2010 and 2020 the 2nd speed can be selected for cutting off and deburring and for cutting smaller threads. Switch the switch (18) rapidly from position 1 to position 2 with the machine running to do this. Press the die head against the rotating  material with the pressing lever (5). After one or two thread turns the die head continues to cut automatically. The die head opens automatically on reaching the standard thread length for tapered pipe threads. For long threads and bolt threads, open the die head manually with the machine running by pressing the closing and opening lever (10) on the left. Release the foot switch (21). Set switch (18) to R. Press the foot switch (21) briefl y, the material is released.
Unlimitedly long threads can be cut by re-tightening the material. To do this, release the foot switch (21) when the tool carrier (2) approaches the machine housing during thread cutting. Do not open the die head. Set switch (18) to R. Release the material, move the tool carrier and material to the right end position with the pressing lever. Switch the machine back on in switch position 1.
To cut pipes, the pipe cutter (15) is swung in and pushed to the desired cutting position using the pressing lever (5). The rotating pipe is cut by turning the spindle to the right. The inside burr created by cutting is removed with the pipe inside deburrer (16).
Draining thread-cutting material in REMS Tornado 2000, 2010, 2020: Pull off the hose from the tool carrier (2) and hold into the container. Let the machine run until the oil tray is empty. or: Remove the oil tray and empty via the spout (17).
Draining thread-cutting material in REMS Tornado 2000 T, 2010 T, 2020 T: Pull off the hose from the tool carrier (2) and hold into the container. Let the machine run until the oil tray is empty. or: Remove the stopper (25) and drain the oil tray.

3.3.2. REMS Magnum
Swing out tools and move the tool carrier to the right end position with the pressing lever (8). Insert the material through the opened guide chuck (2) and the opened quick action hammer chuck (1) so that it protrudes about 10 cm from the quick action hammer chuck (1). Close the quick action hammer chuck until the dies are touching the material. With the clamping ring tighten the material once or twice after a brief opening movement. The material protruding to the rear is centred by closing the guide chuck (2). Swing down and close the die head. Switch the switch (3) to 1, actuate the foot switch (4). REMS Magnum 2000 / 3000 / 4000 is only switched on and off with the foot switch (4), switch (3) is not provided.
In REMS Magnum 2010 / 3010 / 4010 and 2020 / 3020 / 4020 the second speed can be selected for cutting off and deburring and for cutting smaller threads. Switch the switch (3) rapidly from position 1 to position 2 with the machine running to do this. Press the die head against the rotating material with the pressing lever (8). After one or two thread turns the die head continues to cut automatically. The die head opens automatically on reaching the standard thread length for tapered pipe threads. For long threads and bolt threads, open the die head manually with the machine running by pressing the closing and opening lever (14) on the left. Release the foot switch (4). Open the quick action hammer chuck, remove material.
Unlimitedly long threads can be cut by re-tightening the material. To do this, release the foot switch (4) when the tool carrier approaches the machine housing during thread cutting. Do not open the die head. Release the material, move the tool carrier and  material to the right end position with the pressing lever.
Clamp the material again, switch the machine back on. To cut pipes, the pipe cutter (18) is swung in and pushed to the desired cutting position using the pressing lever. The rotating pipe is cut by turning the spindle to the right. The inside burr created by cutting is removed with the pipe inside deburrer (19).
Drain thread-cutting material. Pull off the hose from the tool carrier (7) and hold into the container. Let the machine run until the oil tray is empty. or: Remove the stopper (25) and drain the oil tray.

3.4. Cutting Nipples and Double Nipples
REMS Nippelfi x (automatic inside clamping) or REMS Nippelspanner (inside clamping) are used for cutting nipples. Make sure that the pipe ends are deburred on the inside. Always push on the pipe sections as far as they will go.
To clamp the pipe section (with or without thread) with the REMS Nippelspanner, the head of the nipple tightener is splayed by turning the spindle with a tool. This may only be done with the pipe section fitted.
Makes sure that no shorter nipples than the standard allows are cut with the REMS Nippelfi x and the REMS Nippelspanner.
3.5. Cutting Left-handed Threads
Only REMS Magnum 2010, 2020, 3010, 3020, 4010 and 4020 are suitable for left- handed threads. The die head in the tool carrier must be pinned with an M 10 × 40 screw for cutting left-handed threads, otherwise this can lift and damage the start of the thread.
Mount the changeover valve (accessory Art. No. 342080), see “Tornado/Magnum changeover valve” operating instructions. Set the switch (3) to position “1” and press the foot switch (4) until thread cutting oil emerges from the die head. This vents the system and fills it completely with oil. The flow direction of the coolantlubricant pump is reversed with the lever on the changeover valve (Fig. 9). Set the switch (3) to position “R” to cut left-hand threads.

Maintenance

Notwithstanding the maintenance described below, it is recommended to send in the REMS thread cutting machine to an authorised REMS contract customer service workshop for inspection and periodic testing of electrical devices at least once a year. In Germany, such periodic testing of electrical devices should be performed in accordance with DIN VDE 0701-0702 and also prescribed for mobile electrical equipment according to the accident prevention rules DGUV, regulation 3 “Electrical Systems and Equipment”. In addition, the respective national safety provisions, rules and regulations valid for the application site must be considered and observed.

4.1. Maintenance
WARNING
Pull out the mains plug before carrying out maintenance or repair work!
The gear of the REMS thread cutting machine is maintenance-free. The gear runs in a closed oil bath and therefore needs no lubrication. Keep the clamping and guide chucks, guide arms, tool carrier, die head, REMS dies, pipe cutter and pipe inside deburrer clean. Replace blunt REMS dies, cutting wheel, deburrer blade. Empty and clean the oil tray from time to time (at least once a year). Clean plastic parts (e.g. housing) only with the REMS CleanM machine cleaner (Art. No. 140119) or a mild soap and a damp cloth. Do not use household cleaners. These often contain chemicals which can damage the plastic parts. Never use petrol, turpentine, thinner or similar products for cleaning. Make sure that liquids never get inside the REMS thread cutting machine.

4.2. Inspection/Repair
WARNING
Pull out the mains plug before carrying out maintenance or repair work!
This work may only be performed by qualifi ed personnel.
The motor of REMS Tornado 2000 / REMS Magnum 2000 / 3000 / 4000 has carbon brushes. These are subject to wear and must therefore by checked and changed by qualifi ed specialists or an authorised REMS customer service workshop from time to time.

Behaviour in the event of faults

5.1. Fault: Machine does not start.
Cause:

• Emergency stop button not released.
• Thermal protection switch has tripped.
• Worn carbon brushes (REMS Tornado 2000, REMS Magnum 2000 / 3000 / 4000).
• Connecting lead and/or foot switch defective.
• Machine defective.

5.2. Fault: Machine does not pull through
Cause:

• REMS dies are blunt.

• Unsuitable thread-cutting material.

• Overloading of the electricity mains.

• Too small a cross-section of the extension lead.

• Poor contact at the connectors.

• Worn carbon brushes (REMS Tornado 2000,
  REMS Magnum 2000 / 3000 / 4000).

• Machine defective.

Remedy:

• Release emergency stop button on foot switch.
• Press thermal protection switch on foot switch.
• Have the carbon brushes changed by qualifi ed personnel or an authorised REMS customer service workshop.
• Have the connecting lead and/or foot switch inspected/repaired by an authorised REMS customer service workshop.
• Have the machine checked/repaired by an authorised REMS customer service workshop.

Remedy:

• Change REMS dies.
• Use REMS thread-cutting materials REMS Spezial or REMS Sanitol.
• Use a suitable power source.
• Use cable cross-section of at least 2.5 mm².
• Check connectors, use another outlet if necessary.
• Have the carbon brushes changed by qualifi ed personnel or an authorised REMS customer service workshop.
• Have the machine checked/repaired by an authorised REMS customer service workshop.

5.3. Fault: No or poor feeding of thread-cutting material at the die head.
Cause:

• Coolant-lubricant pump defective.
• Too little thread-cutting material in the oil tray.
• Screen in the suction nozzle soiled.
• Hoses on the coolant-lubricant pump switched.
• Hose end not pushed onto nipple.

5.4. Fault: The REMS dies are open too wide despite the right scale setting.
Cause:

• The die head is not closed.

5.5. Fault: Die head does not open.
Cause:

• Thread was cut to the next biggest pipe diameter with the die head open.
• Length stop folded away.

5.6. Fault: No useful thread.
Cause:

• REMS dies are blunt.
• REMS dies inserted incorrectly.
• No or poor feeding of thread-cutting material.
• Poor thread-cutting material.
• Feed movement of the tool carrier obstructed.
• Pipe material is unsuitable for thread cutting.

5.7. Fault: Pipe slips in chuck.
Cause:

• Dies heavily soiled.
• Pipes have thick plastic coating.
• Dies worn.

Remedy:

• Change coolant-lubricant pump.
• Refi ll thread-cutting material.
• Clean screen.
• Switch over hoses.
• Push hose end onto nipple.

Remedy:

• Close the cutting head, see 3.1. Tools, Changing the REMS dies.

Remedy:

• Close the cutting head, see 3.1. Tools, Changing the REMS dies.
• Set the length stop for closing and opening lever in the same direction.

Remedy:

• Change REMS dies.
• Check numbering of dies to die holders, change REMS dies if necessary.
• See 5.3.
• Use REMS thread-cutting materials.
• Loosen wing nut of tool carrier. Empty chip tray.
• Only use approved pipes.

Remedy:

• Clean dies.
• Use special dies.
• Change dies.

Disposal

The thread cutting machines may not be thrown into the domestic waste at the end of use. They must be disposed of properly by law.

Manufacturer’s Warranty

The warranty period shall be 12 months from delivery of the new product to the first user. The date of delivery shall be documented by the submission of the original purchase documents, which must include the date of purchase and the designation of the  product. All functional defects occurring within the warranty period, which are clearly the consequence of defects in production or materials, will be remedied free of charge. The remedy of defects shall not extend or renew the warranty period for the product. Damage attributable to natural wear and tear, incorrect treatment or misuse, failure to observe the operational instructions, unsuitable operating materials, excessive demand, use for unauthorized purposes, interventions by the customer or a third party or other  reasons, for which REMS is not responsible, shall be excluded from the warranty Services under the warranty may only be provided by customer service stations authorized for this purpose by REMS. Complaints will only be accepted if the product is returned to a customer service station authorized by REMS without prior interference and in a fully assembled condition. Replaced products and parts shall become the property of REMS.
The user shall be responsible for the cost of shipping and returning the product.
A list of the REMS-authorized customer service stations is available on the Internet under www.rems.de. For countries which are not listed, the product must be sent to the SERVICE-CENTER, Neue Rommelshauser Strasse 4, 71332 Waiblingen, Deutschland. The legal rights of the user, in particular the right to make claims against the seller in case of defects as well as claims due to wilful violation of obligations and claims under the product liability law are not restricted by this warranty.
This warranty is subject to German law with the exclusion of the confl ict of laws rules of German International Private Law as well as with the exclusion of the United Nations Convention on Contracts for the International Sales of Goods (CISG). Warrantor of this world-wide valid manufacturer’s warranty is REMS GmbH & Co KG, Stuttgarter Str. 83, 71332 Waiblingen, Deutschland.

Spare parts lists

For spare parts lists, see www.rems.de → Downloads → Parts lists.

EC Declaration of Conformity
We declare under our sole responsibility that the product described under „Technical Data“ is in conformity with the standards below mentioned following the provisions of Directives 2006/42/EC, 2014/30/EU, 2011/65/EU, 2015/863/EU, 2019/1781/EU, 2009/125/EG.
Declaration of Conformity (UK)
We declare under our sole responsibility that the product described under “Technical Data” is in conformity with the standards below mentioned following the provisions of Supply of Machinery (Safety) Regulations 2008 S.I. 2008/1597 (as amended), S.I. 2016/1091 (as amended), S.I. 2012/3032 (as amended), S.I. 2010/2617 (as amended) and the directive 2019/1781/EU.

EN 62841-1:2015 + A11:2022-04, EN 62841-3-12:2019, EN 55014-1:2017/A11:2020-03, EN IEC 55014-2:2021-03, EN IEC 61000-3-2:2019/A1:2021-04, IEC 61000-3-3:2013 + A2:2021-03, EN 62233:2008, EN 60204-1:2019

REMS GmbH & Co KG
Stuttgarter Straße 83
71332 Waiblingen
Deutschland
2023-03-15

Template for REMS Tornado on workbench

REMS Tornado mounted on REMS Jumbo collapsible workbench with height- adjustable material support REMS Herkules Y.

References

• REMS GmbH & Co KG
• REMS GmbH & Co KG

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