_ Ballec BalTec RADIAL Riveting Machine Operating Manual Machine Type: — RN-280 Machine No.: Power Supply BEFORE TURNING ON SPINDLE HEAD. READ PAGE 2 SPINDLE LUBRICATION This machine is equipped with tool holder/pressure cup R = It is important that you read these working instructions carefully before you operate the BalTec RADIAL Riveting Machine, ‘This will acquaint you with the various working possibilities offered by the new BalTec RADIAL Riveting technique. ‘We believe that the machine will meet your requirements for reliability and productivity and we thank you for your confidence. BalTec (formerly Bracker Corporation) 130 TECHNOLOGY DRIVE Telephone: 724-873-5757 CANONSBURG, PA 15317 Telefax: 724-873-5858 WEBSITE: www.baltecorporation.com‘Technical data Fat_280 and ANE 280, capacity (rivet shank aia. of tensile strength 370 W/nm2) Motor performance Motor speed Air pressure Riveting pressure Riveting time Working stroke Weights: RHE 260 RN 280 Control box 1 to 12 mm 0.03" to 0.47" oo ae 1800 rpm at 60 cps supply 1500 rpm at 50 cps supply 1 to 6 bar 14 to 88 pat max. 1700 da max. 3740 Ibs 0.1 to 5.3 see. 5 to 40 mm 0.2" to 1.57" s2kg ) 114 Ibs) 160 kg) 330 Ibs ) 10 ke 22 Ihe (including control box) SNAP PEEN LENGTHS SEE PAGES 5 AnD 16Index bescripti 2 10. norating and checking Moving machine Power supply Poot ewitch / 2 dual pash buttons: - Compressed air supply 5.1 air connection 5.2 Air maintenance device Lubrication 6.1 Lubrication by hand 6.2 Automatic lubrication system 6.3 Recommended o11 brands for lubrication of machine - Operation 7.1 Height adjustment 1.2 Rajustuont of spindle stroke 7.3 Starting and stopping machine 7.4 Setting machine for operation 7.5 Semi automatic operation 7.6 Work Light. 7.7 Riveting preseure adjustment. 7.8 Stroke speed adjustment Tools . Various riveting methods Riveting with positive stroke Riveting without stroke stop Riveting with high preasure Riveting with low pressure Riveting with device for holding down Useful hints Page enue abravings Detatts of machine Details of control box Dimensions of machine Dimensions of control box Instructions for automatic lubrication system Bijur ‘types of snap peens and rivet heads Manufacture of snap peens Materials for the manufacture of snap peens Shape of snap peon profile for crown rivet heads Snap peens with different tength Tubrication system Pneumatic system Diagram of electrical control system and cable arrangenent Machine boay with spare parts List Machine bracket with spare parts List Riveting spindle head with spare parts List Motor with spare parts List Control box with spare parts List tubrication with spare parts list Foot pedal switch with spare parts List Povice for holding down with spare parts List 2 dual push buttons with spare parts List Moving machine Automatic Lubefeation for riveting unit Finger guard Appendix Mat of available snap peens Solutions (2 pages) Page 10 u 2 13 14 15 16 20 a 2 23 2a 25 26 27 28 29 2 a a< Moving machi care should be taken when uncrating the well-anchored machine and any damage should be reported to the carrier immediately. See page 29. supply In_the separate control box (22) at the inner side of the connection heard (47), you will find the terminal strip for connecting the power supply (49) - When Ieosening screw (48), the connection board can be tilted upeards. Nake sure that voltage of the power outlet corresponds with voltage narked on the machine. A diagram of electric control aystem and cable arrangenent is enclosed ‘The direction of rotation of the motor 1s of no importance since st does not affect the machine performance. - Foot switen / 2 dual push buttons The Foot ewitch (8), linked by cable to the electric control box, controls the riveting stroke. In case your machine is equiped with 2 hand operation (9), the riveting stroke is released by the 2 dual push buttons. Roth buttons must be pressed simultaneously within a time interval of approx. 0.5 see. . Compressed air supply 5.1 aie ‘Mhe air connection (35) R 1/4" is situated at the rear of the control box. 5.2 abe we nce device In the separate control box you will find an air filter/drainer (42) and miat lubeieatar (43). In case your machine is equiped with a finger pro- tection device (25), a pressure regulator, Filter/drainer and mist lubricator (43) is foreseen. Functions of the aiv maintenance device: a) separation of condensed water and impurities DD permanent Lubrication through the air stream of the alr operated element's ‘The slots at the side of the control box permit to check Levels of O11 and condensed water, Access ta the air maintenance unit by lifting Tight hand part of cover of control box. Nake sure that there Ls always 9 sufficient quantity of o11 according to the following recommendations in the mist lubricator (43). When re~ Filling of1, the compresced air supply should be shut off, before re~ moving the Glass container. Do not fill more oil than 10 am (0.4") underneath the edge of the containerCondensed water has to be drained regularly by the drain Line (45). ‘To do 0, Lift drainer (46) slightly. The level of condensed water must not mount above the baffleplate (taximun-mark) . Recommended of} brands for nist: lubricating unit pp Energol RD-E 46. (150) chevron Vistac O11 38 (150) SSO Arox EP 15 (150) oem. Mobi larma 522 suELL Torcula O11 32 (180) ‘Texaco Rock DrLLL bub 46x1,. (150) YALVOLINE PP O11 No. 10 6. Lubrication 6.1 Lubrication by hand Position of oll injection nipple (3) see page 7. Give 2 to 3 shots with ofl press supplied with machine, once a week at B-hours day. When working with higher pressure or when working in 2 to 3 shifts, lubrication has to be repeated at shorter intervals, or machine to he equiped vith an automatic lubrication system. Autonatic lubrication system Machines equiped with automatic lubrication system, have a selector switch (12). Position I of this selector ewitch means "PERMANENT LUBRICATION" and position If "PRELUBRICATION" . ‘The quantity Of O13 delivered in position "PRELUBRICATION" is approx. 500 mm3/min. After a machine stop of 5 hours, switch to "PRELUBRICATION" for approx. 5 min. After a repair on the riveting spindle, the “PRELUBRICATION" Should be set until of1 is appearing on the work spindle head (6). The 2 lubrication positions work with running motor only. With selector switch set in "PERMANENT LUBRICATION", the quantity of eit delivered into the riveting spindle is of approx. 4 mm/min. ‘To double this quantity, the dosaging valve Wo. 3/0, normally built in this automatic Tubrication system, can be replaced against a dosaging valve No. 00 (see diagram of lubricating system on pago 17). This higher dose should be used when machine has to operate under heavy conditions. ‘The lubricant is [11lea into the container of the automatic lubricating system by the filling hole (13). the slot (14) in the machine body permits to check the ofl level. For details see maintenance sheet of Bijur Products tne. on page 11. Rocomuonded oil brands for lubrication of machine ‘The following oil brands are recommended for lubrication by hand as well as for automatic lubrication SHELL mala Of1 160 (150) (1 can sent with machine) NoBIE, Hobil Gear 626 cour EP Lubricant uD 100 (150) RP Enecgol GR-XP 150 (180) SSO Spartan EP 100 (150) vatwonine BPC/MP 1IMPORTANT: Ploase make sure that machine ia lubricated hefore starting operation or after a longer standstill. WARNING: bo not tse grease! Once a week, the bright portions of machine bracket and machine table should be cleaned with an oiled cloth. 7. Operation ma 12 7.6 Height adjustment Use crank handle (10) to loosen clamp nuts (11), as well as to move riveting unit up and down. Tighten clap nuts again before riveting. Adjustment of spindle ctxoke ‘The adjustment of spindle stroke is done by turning on the stroke adjustment ring (1) after loosening the clamp screw (2), This has to be tightened again before riveting. 1 graduation on the stroke adjustment ring » 0.01 mm of stroke. Starting and stopping machine The machine is started and stopped by the main switch (30). The signal lamp (32) Lights up when the machine Is switched on. Setting machine for operation Bofore setting, raise riveting unit high enough to allow room to place the fixture, introduce the work piece and insert the snap pen. Set selector switch (31) in position "serrinc" le. riveting time can now be controlled by pressing and holding the foot switch down (or pressing the 2 dual push buttons) « By turning the graduated stroke adjustment ring (1), adjust the tool stroke to a minimum to prevent the tool From striking into the work piece holder. Thereafter, micro adjustuent of the stroke Length can be started, Semiautomatic operation Set selector switch (31) on position *smmr-autowrs Lf. riveting time is now adjusted by step switeh (G4). Selected time = riveting time in cluding feed tine of riveting spindle. Press foot switch or the 2 dual push buttons to release one riveting operation. Fach consecutive riveting operation is again started with the foot switch or the 2 dual push buttons. Semi automatic operation should be used only after a few trial rivetings with machine set as described in paragraph 7.4. Work Light Use switeh (24) on the Lamp for work Light (23).7.7 Riveting pressure adjustment ‘he alr pressure 4s adjusted by turning the knob on the air regulating valve (37) in the control box. It determines the working pressure of the snap peen and is infinitely adjustable between 1 and max. 6 bar (14 and 88 psi). The following riveting pressures are thus obtainable: F (vos) [dan] 1000 1800] 7.8 Stroke speed adjustment ‘The spindle stroke speed is adjusted by the speed adjustment valve (16) on the riveting unit. ay turning the set screw clockwise, this speed is reduced. 8. Tools {snap pens) ‘The required enap peen (7) is inserted into the work spindle head (6) and Ls held by @ permanent magnet. The form or shape of the finished rivet heads depends on the design of the cnap peen. A number of difforent types of snap peons and rivet heads is {illustrated on page 12.SNAP PEEN LENGIH: ‘The various snap pean lengths are shown on page 16. Tt is absolutely necessary to observe these lengths in order that the center of the snap peen profile meets with the axis of the riveting spindle: In case too a short oF too a long snap peen is used, a lateral pressure will be generated which may cause the tool holder to Lift from the pressure cup and damage the latter. axis of riveting spindle pressure cup tool holder snap peen 9. Various riveting methods 9.1 Riveting with positive atroke Adjust stroke with adjustment ring (1) for positive stroke stop. This is recommended for rivets or assemblies with uniform tolerance. 9.2 Riveting without stroke sto For assemblies with irregular tolerances. Instead of a positive stroke stop, the selected riveting time governe the mechanical stroke stop. ‘The stroke adjustment must be set so that the snap peen cannot rivet into the support. Correct riveting pressure and riveting time are essential for flawless riveting. 9.3 Riveting with hia! \ pees: 1@ use Of high pressure allows a shorter riveting time. This procedure is recommended for assonblies riveted down tight or which will be subject to strong mechanical stress or pressure.9.4 Riveting with low pressure For brittle material, ceramics, moulded plastic, ete. and for loose fit or rotating parts, select longer riveting time with reduced pressure. Also bending or swelling of rivet shaft can be avoided by riveting with low pressure. It may he necessary:to reduce the doun stroke speed of riveting spindle (see paragraph 7.8). 9.5 Riveting with device for holding (see page 27) For assemblies that have to be held together or pressed together before riveting. ‘The pressure depends on number and thickness of cup springs, ag well as ‘on the thickness of the pressure pad. This latter has to be made to suit the component. When using a device for holding down, a snap poen of at least 84 mm is necessary; L.e. tool holder and pressure cup R116. Longer snap peens can also be used if required, with suitable tool holder and pressure cup, Gepending on parts to be riveted (see page 16) 10. Useful hints 10.1 Working with shortest possible stroke saver time and air consumption. 10.2 Try to establish minimum riveting time. 10.3 Rivet shafts can be shorter than is customery with conventional (hammering or spinning) riveting machines. 10.4 For the riveting of assenblies with difficult accessibility (for ingtance at undercuts, recesses or near angles ete.), longer than standard size snap peens are available (see page "Snap peens of different Lengths"). Extra long snap peons require a special tool holder with corresponding pressure cup. Exchanging the standard with the special parts takes Dut a few minutes.ole | ti Rel rf 5 xt 2 ej] a} it i Wy is 29° 38s Aenderung: Index a 11.8.87 802.125 RN 280 cADg-96 chamfered edge max. 0.2 mm x 45° (0,007" x 45°) TYPES OF SNAP _PEENS AND RIVET HEADS Material pen see page 14 Measures Dz and La see pages 13 and 16 l W 2 < X Xx wT N AS NERS SRS Ni SS 1. Standara_ type Flat, y= 11. Spee: flat conical crown Flanged Flanged shouldered (counter~ — (counter-—_(counter- bore) bore) bore) shouldered {counter hore) A Q 8 B® ag Were: Z Ms Z TIT, Special type ponents we would he TR heh aMANUFACTURE OF SNAP PEENS style A Style B vwelth round HS) point Fi Style D {tel Le 1a = grinding after 23 = hardening in of, 31 = polishing @—* 26 = tempering © 45 13MATERIALS FOR THE MANUFACTURE OF SNAP PEENS chart pIn- | Material | Hardness Heat-creatment efinition | No. max. warden’ ‘temperin rateriar | Definition | hardening spering 90 wa ve_| 1.2842 63-65 wre| s00-850” ¢ | 100-3007 Analysis ce st Bn P s ce v . . ’ ae ae . . 0.85-0.94 0.15-0.30 |1-90-2.10 | 0.030 | 0.030} 0.20-9.50 | 0.05-0.15 pp ‘To rivet standard rivet-materials ae t standard terial Standard and special execution (see page 12) ‘anap peens| chart 11 DIN- | Material, | Hardness eat-treatment wateriar | Pefinition| No. max. hardening tempering s 6-5-2 | 1.3343 64-66 arc] 1190-1240" c| 540-560" c Analysis © st Mn P s | cr | mw | v w . safse|{ ss] se] ¢ 2 * 4 0.81-0.92 | 0.45 | 0.20 | 0.030 | 0.030 | 3.80- | 4.70-| 1.70- | 6.00- 4:50 | 5.20 | 2.00 | 6.70 lee ‘To rivet heat-trea! ee To rivet heat-treated Range OF [standard and special execution (# wy snap pecns| me pags Special snap peons For economical reasons Lt 1s sometimes advisable to use 2 different material: —__Frame of tool steel, Ansert: according to application as per ret 14SHAPE OF SNAP EN PROFILE FOR CROWN RIVET HEADS (Wasim admissible depth of crown profile for snap pen length of 68 mn) 15SNAP PEENS WITH DIFFERENT LENGTH ‘Tool holder SSS WS os ec Free Type of angie d. | height # machine u_| inch pa | inch soar 2 | aaa RN/NE ee lo.5503] 4° 47" 45 177 oo (0.5505, Scant 132 #10 or | aa0 148. 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