Avdel 07900-09080 User manual

0
0
20
40 60
80
100
1
2
34
5
6
7
lbf/in
2
bar
CALIBRATIONdue
07900-09080
Instruction Manual
Original instruction
Broach Load Test Power Tool
07900-09080
Speed Fastening Applications

3
Contents
Safety Rules 4
Tool Specifications 5
Intent of Use 5
Putting into Service
Air Supply 6
Loading the Tool 6
Cursor 6
Nose Equipment 6
Operating Procedure 7
Air Pressure Graph vs Broach Load 8
Mandrel Life Table 9
Avdel UK Limited policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice.
Warranty
Avdel UK Limited installation tools carry a 12 month warranty against defects caused
by faulty materials or workmanship, the warranty period commencing from the date of
delivery confirmed by invoice or delivery note.
The warranty applies to the user/purchaser when sold through an authorised outlet,
and only when used for the intended purpose. The warranty is invalidated if the
installation tool is not serviced, maintained and operated according to the instructions
contained in the Instruction and Service Manuals.
In the event of a defect or failure, and at its sole discretion, Avdel UK Limited
undertakes only to repair or replace faulty components.

4
Safety Rules
1Do not use outside the design intent.
2Do not use equipment with this tool/machine other than that recommended and supplied by Avdel UK Limited.
3Any modification undertaken by the customer to the tool/machine or any equipment supplied by Avdel UK Limited or their
representatives, shall be the customer’s entire responsibility. Avdel UK Limited will be pleased to advise upon any proposed
modification.
4The tool/machine must be maintained in a safe working condition at all times and examined at regular intervals for damage and
function by trained competent personnel. Any dismantling procedure shall be undertaken only by personnel trained in Avdel UK
Limited procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact
Avdel UK Limited with your training requirements.
5The tool/machine shall at all times be operated in accordance with relevant Health and Safety legislation. In the U.K. the “Health
and Safety at Work etc. Act 1974” applies. Any question regarding the correct operation of the tool/machine and operator safety
should be directed to Avdel UK Limited.
6The precautions to be observed when using this tool/machine must be explained by the customer to all operators.
7Always disconnect the airline from the tool/machine inlet before attempting to adjust, fit or remove a nose assembly.
8Do not operate a tool/machine that is directed towards any person(s).
9Always adopt a firm footing or a stable position before operating the tool/machine.
10 Ensure that vent holes do not become blocked or covered.
11 Do not operate the tool if it is not fitted with a complete nose assembly or swivel head unless specifically instructed otherwise.
12 When using the tool, the wearing of safety glasses is required both by the operator and others in the vicinity to protect against
fastener ejection, should a fastener be placed ‘in air’. We recommend wearing gloves if there are sharp edges or corners on the
application.
13 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool which should
be kept dry and clean for best possible grip.
14 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent start up.
15 The combination of fastener, mandrel, hole size and sheet thickness shall be in accordance with specifications set by Avdel UK
Limited.
16 The cylinder of the tool must be free to move without risk of hitting or trapping the operator.
This instruction manual must be read with particular attention to the following safety rules, by any person
operating this tool.
IMPORTANT
While a small amount of wear and marking will naturally occur through normal and correct use of mandrels,
they must be regularly examined for excessive wear and marking, with particular attention to the head
diameter, the tail jaw gripping area of the shank or heavy pitting of the shank and any mandrel distortion.
Mandrels which fail during use could forcibly exit the tool. It is the customer's responsibility to ensure that
mandrels are replaced before any excessive levels or wear and always before the maximum recommended
number of placings. Contact your Avdel UK Limited representative who will let you know what that figure is by
measuring the broach load of your application with a calibrated test tool. These tools can also be purchased
under Part Number 07900-09080, supplied with all necessary information for testing in this manual.

Intent of Use
Specification
5
Air Pressure Maximum 7 bar
Free Air Volume Required @ 5.5 bar 1.72 litres
Noise Level Less than 70 dB(A)
Weight Without nose equipment 3.0 kg
Vibration Less than 2.5 m/s2
This particular test tool is to be used solely with Avdel®speed fasteners supplied by Avdel®. The precise list of fasteners appears in
the mandrel life table page 9. The tool is supplied without any nose equipment as it is fundamental that this tool is used fitted with the
exact same nose equipment as that used on the placing tool you have selected to place your fasteners. Tools can be purchased under
part number 07900-09080 or you may contact your local Avdel representative to test your application.
The test tool can be used to define the ideal combination of tool/nose equipment/fastener for your application and in any case MUST
be used prior to the actual placing tool in order to define the broach load exerted on the mandrel when placing a fastener in the
application. IT IS ESSENTIAL TO ESTABLISH THE BROACH LOAD TO PREVENT OVER-USAGE OF MANDRELS AND RISK BREAKAGE
AND INJURY.
The intensity of the broach load will vary with the level of interference between the diameters of the fastener, of the mandrel head and
of the hole in the application as well as with the thickness of the application. SPEED FASTENING DEMANDS RIGOROUS OBSERVATION
OF RECOMMENDATIONS laid down in fastener technical data sheets and in the selection process of nose equipment laid down in
instruction manuals.
When putting the test tool into operation, its gauge will display the air pressure at which a particular fastener will place in a specific
application with defined nose equipment.
The graph on page 8, will allow you to convert that air pressure (bars) into a broach load (Newtons) which in turn can be
translated, using the table page 9, into a maximum safe number of placings for that series of fasteners with the exact
same nose equipment you will use with your placing tool AND in random samples of your actual application.

Air Supply
Loading the Tool
Cursor
Nose Equipment
Putting into Service
6
This tool operates with compressed air at a maximum pressure of 7 bar. We recommend that you temporarily make use of the air
supply set up for your actual placing tool with precautions as described in the instruction manual for your placing tool.
IMPORTANT
It is essential that the correct nose equipment is fitted to the tool to ensure both effective placing of the
fastener and SAFE operation of the tool.
IMPORTANT
It is essential to check that the cursor orientation before attempting to operate the tool.
The procedure for loading the tool with fasteners and for fitting the nose equipment to the tool are integral. Refer to the instruction
manual for your specific placing tool EXCEPT FOR 1.6MM (1/16”) AVLUG®WHICH SHOULD BE LOADED ONE AT A TIME PER TEST AS
THE TEST TOOL CANNOT EXACTLY EMULATE THE 07176 PLACING TOOL USED FOR PLACING THIS FASTENER.
To avoid complete dismantling of the tool check the orientation
of the cursor before fitting the nose equipment to the tool. If
fitted incorrectly, the cursor will not allow feeding of the
fasteners. When fitted the correct way round, the cursor will
easily slide out of the barrel when a mandrel is pushed into its
centre then pulled back. To reverse the orientation of the
cursor, refer to the instruction manual for your particular
placing tool. The sprung loaded, slightly concave, end of the
cursor should point towards the front of the tool as shown
right.
NOSE
JAWS
TOOL
BARREL
CURSOR
SPRING
LOADED END
Fit the same mandrel, follower spring and nose jaws as you intend to fit on the tool which you have selected to place your fasteners
following the ‘tool loading’ instructions in the manual for that tool.

7
Operating Procedure
Putting into Service
IMPORTANT
The test tool MUST be returned to Avdel UK Limited at minimum every 6 months for re-calibration.
A new manual with an updated air pressure versus broach load graph will be supplied in English and in the
official language of your country if EC regulations apply.
NO MAINTENANCE WHATSOEVER MAY BE CARRIED OUT ON THIS TOOL BY ANYONE OTHER THAN
SPECIFICALLY TRAINED AND DESIGNATED AVDEL PERSONNEL. FOLLOWING MAINTENANCE, THE TOOL
MUST BE RE-CALIBRATED PRIOR TO FURTHER USE.
READ THE SAFETY INSTRUCTIONS page 4 carefully.
•Connect the test tool to the air supply.
•Set the gauge on the test tool to zero actuating the
trigger to ensure a true reading.
•Fit the exact same nose equipment to the test tool as
you intend to use on the tool you will be using to place
the fasteners in your application and as recommended in
the instruction manual for your specific tool. Note that
when testing 1/16” Avlug®fasteners NO POD must be
used. A single fastener must be fed at a time. To fit the
nose equipment, follow the ‘Loading the tool’ procedure
in the instruction manual for your placing tool.
•Switch on tail jaws by operating slider valve.
•Offer the protruding fastener into the application applying
a little pressure to ensure that the fastener head rests
against the application (This is crucial to obtain a true
reading).
•Hold the trigger in and SLOWLY raise the air supply pressure until the fastener places. Keeping the trigger held, read the air
pressure off the gauge before releasing the trigger.
•The mandrel is pulled through the fastener which is formed into the application.
•Remove the application. The next fastener will automatically be presented through the front nose jaws, ready for placing.
•The highest of at least 10 readings should be used.
•As the test tool was calibrated, the graph on page 8 will convert the air pressure reading in bars into a broach load in newtons.
TO CONVERT THE BROACH LOAD INTO A MAXIMUM NUMBER OF FASTENER PLACINGS PER MANDREL
•Locate your broach load reading on the scale at the top of the table on page 9 and on the left-hand side, find the line with your
fastener (name and size).
•The maximum recommended number of fastener placings with one mandrel will be shown where they intersect. THIS NUMBER OF
PLACINGS MUST NOT BE EXCEEDED. In case of doubt contact Avdel Fastening Systems for advice.

8
Air Pressure Graph vs Broach Load

9
Mandrel Life Table
MAXIMUM NUMBER OF FASTENER PLACINGS PER MANDREL MAX. LOAD AT
Fastener Tool Broach Load (lbf / N) 5000 PLACINGS
(for which the 100 / 110 / 120 / 130 / 140 / 150 / 160 / 170 / 180 / 190 / 200 / 225 / 250 / 275 / 300 / 325 / 350 / 375 / 400 / 450 / 500 / 550 / 600 / 650 / 700 / 750 / 800 / 850 / 900 /
mandrel is used) 445 489 538 582 627 672 717 762 806 851 896 1008 1120 1232 1344 1456 1568 1680 1792 2016 2240 2464 2688 2912 3136 3360 3584 3808 4032 lbsf N
1/16 Avlug 26000 20000 13000 XXXXXX XXXXXXXXXXX X XX X X X X X X X 127565
3/32 Briv 45700 36300 32500 28800 25100 23400 16000 10200 X XXXXXXXXXXX X XX X X XXXXX177787
2.8mm Rivscrew 50000 30500 25100 20900 16200 14600 13200 10400 8710 7240 6110 XXXXXXXXX X XX X X XXXXX214952
3mm Rivscrew 50000 30500 25100 20900 16200 14600 13200 10400 8710 7240 6110 XXXXXXXXX X XX X X XXXXX214952
2.5mm Avtronic 50000 50000 50000 49000 38900 35100 32400 29500 26600 23700 20400 11200 XXXXXXXX X XX X X X XXXX2411072
# 3/32 Avlug 50000 50000 50000 50000 43200 37200 33900 31600 28800 26300 23200 14500 XXXXXXXX X XX X X X XXXX2441085
3/32 Avlug 50000 50000 50000 50000 50000 40300 35900 33300 30900 28200 25700 18000 6920 XXXXXXX X XX X X X XXXX2581148
3/32 Chobert 50000 42600 33500 28200 23400 20400 17400 15000 12900 10800 9300 6400 XXXXXXXX X XX X X X XXXX2421077
3/32 Grovit 50000 42600 33500 28200 23400 20400 17400 15000 12900 10800 9300 6400 XXXXXXXX X XX X X XXXXX2421077
2.5mm Avsert 50000 42600 33500 28200 23400 20400 17400 15000 12900 10800 9300 6400 XXXXXXXX X XX X X XXXXX2421077
4-40 UNC Avsert 50000 42600 33500 28200 23400 20400 17400 15000 12900 10800 9300 6400 XXXXXXXX X XX X X XXXXX2421077
1/8 Avlug --50000 50000 50000 50000 48400 39800 35900 34500 30900 25700 19100 10800 XXXXXX X XX X X X XXXX2911294
2.8mm Avtronic 50000 50000 50000 50000 50000 50000 50000 44200 38500 35500 33100 27900 21900 14600 XXXXXX XXX X X X X X X X 2951312
1/8 Chobert --50000 50000 41700 35100 29500 26000 22600 20200 18000 12200 9660 7080 5250 XXXXX X XX X X X X X X X 3051357
1/8 Grovit --
50000 50000 41700 35100 29500 26000 22600 20200 18000 12200 9660 7080 5250 XXXXX X XX X X X X X X X 3051357
3mm Avsert ----41700 35100 29500 26000 22600 20200 18000 12200 9660 7080 5250 XXXXX X X X X X X XXXX3051357
6-32 UNC Avsert ----41700 35100 29500 26000 22600 20200 18000 12200 9660 7080 5250 XXXXX X X X X X X XXXX3051357
1/8 Briv ----50000 50000 50000 50000 50000 44200 38500 33100 28200 22900 16800 8510 XXXX X X X X X X XXXX3381504
1/8 Briv (St.Steel) ---------
50000 50000 41000 34600 30500 26000 20900 15700 8900 XXXXXXXXXXXX3901735
3.5mm Rivscrew ----50000 50000 50000 50000 34700 30200 26600 20400 15800 12200 9550 7410 5820 X X X X X X X X X X X X X 362 1610
5/32 Briv -----------32400 25100 20200 16400 13200 10700 8710 7000 X X X X X X X X X X X 443 1971
4.0mm Rivscrew -------
50000 50000 50000 44200 32400 25100 20200 16400 13200 10700 8710 7000 X X X X X X X X X X X 443 1971
4.8mm Rivscrew -------50000 50000 50000 44200 32400 25100 20200 16400 13200 10700 8710 7000 X X X X X X X X X X X 443 1971
5/32 Chobert ----------
48400 35100 26600 21900 17600 14500 11700 9660 7760 5190 X X X X X X X X X X 456 2028
5/32 Grovit ----------48400 35100 26600 21900 17600 14500 11700 9660 7760 5190 X X X X X X X X X X 456 2028
5/32 Briv (St.Steel) ----------------
25100 22400 18600 13600 10500 7590 5620 XXXXXXX6222767
3/16 Briv --------------50000 50000 47900 38500 32700 24300 19700 15500 12200 9660 7500 6100 X X X X 784 3488
3/16 Chobert --------------
50000 50000 47900 38500 32700 24300 19700 15500 12200 9660 7500 6100 X X X X 784 3488
3/16 Grovit --------------50000 50000 47900 38500 32700 24300 19700 15500 12200 9660 7500 6100 X X X X 784 3488
3/16 Briv (St.Steel) -------------------
35900 27500 22600 18400 15000 12200 10500 8700 7000 5500 X 922 4101
6mm Briv ------------------50000 35900 27500 22600 18400 15000 12200 10500 8700 7000 5500 X 922 4101
1/4 Chobert ------------------
50000 35900 27500 22600 18400 15000 12200 10500 8700 7000 5500 X 922 4101
TO CONVERT THE BROACH LOAD INTO A MAXIMUM OF FASTENERS PLACINGS PER MANDREL
• • •
Locate your broach load reading on the scale at the top of the table and on the left-hand side, find the line with your fastener (name & size). The maximum recommended number of fastener placings with one mandrel will be shown where they intersect. THIS NUMBER OF PLACINGS MUST NOT BE EXCEEDED. In case of doubt contact Avdel UK Limited Where the achieved broach load is in between two values on the scale at the top of the table, use the higher table value to determine the mandrel life
Note
• • •
# Denotes using long mandrel 3/16 Briv, 6mm Briv & 1/4 Chobert - At higher broach loads, tool air pressure may need to be Circa 90PSI Any application which results in a broach load in excess of that stated for a mandrel life of 5000 rivet placings (Refer to right hand column of table) should be referred to Avdel UK Limited.
XBroach Load is too high - If close to the lowest number of placings, contact Avdel UK Limited for advice
Never use mandrels to place more than 50000 placings or more than the highest number shown
-

10
Notes

Declaration of Conformity
We, Avdel UK Limited, Watchmead Industrial Estate, Welwyn Garden City, Herts, AL7 1LY
declare under our sole responsibility that the product:
Model: Broach Load Test Power Tool
Serial No. ................................................
to which this declaration relates is in conformity with the following standards:
EN ISO 12100 - parts 1 & 2
BS EN ISO 8662 - part 6 BS EN ISO 11202
BS EN ISO 3744 BS EN 982
ISO EN 792 part 13 - 2000 BS EN 983
following the provisions of the Machine Directive 2006/42/EC
This box contains a power tool which is in
conformity with Machines Directive
2006/42/EC. The ‘Declaration of Conformity’
is contained within.
Date of issue
A. Seewraj - Product Engineering Manager - Automation Tools

Since 1 936 2010Since 1922
www.avdel-global.com
www.infastech.com
02.2011 • © 2010 Infastech
Autosert®(equipment), Avbolt ®, Avdel®, Avdelmate®, Avdel TX2000®, Avdelok®, Avex®, Avibulb®, Avinox®, Avinut™, Avlug
®, Avmatic®, Avplas®,
Avseal®, Avsert®, Avtainer®, Avtronic®, Briv®, Bulbex®, Chobert®, Eurosert®, Fastriv®, Finsert®, Genesis®, Grovit®, Hemlok®, Hexsert®, Holding
your world together®, Hydra®, Interlock®, Klamp-Tite®, Klamptite KTR®, Kvex®, Maxlok®, Monobolt®, Monobulb®, Neobolt®, Nutsert®, Nutsert
SQ®, Portariv®, Rivmatic®, Rivscrew®, Speed Fastening®, Squaresert®, Stavex®, Supersert®, Thin Sheet Nutsert®, Titan®, T-Lok®, TLR®, TSN®,
TX2000®, Versa-Nut®, Viking®and Viking360®are trademarks of Avdel UK Limited. Infastech™ and Our Technology, Your Success™ are
trademarks of Infastech Intellectual Properties Pte Ltd. The names and logos of other companies mentioned herein may be trademarks
of their respective owners. This document is for informational purposes only. Infastech makes no warranties, expressed or implied, in this
document. Data shown is subject to change without prior notice as a result of continuous product development and improvement policy.
Your local Avdel representative is at your disposal should you need to confirm latest information.
AUSTRALIA
Infastech (Australia) Pty Ltd.
891 Wellington Road
Rowville
Victoria 3178
Tel: [phone]
Fax: [phone]
[e-mail]
CANADA
Avdel Canada Limited
1030 Lorimar Drive
Mississauga
Ontario L5S 1R8
Tel: [phone]
Fax: [phone]
infoA[email protected]
CHINA
Infastech (China) Ltd.
RM1708, 17/F., NanyangPlaza,
57 HungTo Rd., Kwun Tong
HongKong
Tel: [phone]
Fax: [phone]
[e-mail]
FRANCE
Avdel France S.A.S.
33 bis, rue des Ardennes
BP4
75921 Paris Cedex 19
Tel: [phone]
Fax: [phone]
AvdelF[email protected]
GERMANY
Avdel Deutschland GmbH
Klusriede 24
30851 Langenhagen
Tel: [phone]
Fax: [phone]
[e-mail]
INDIA
Infastech Fastening Technologies
India Private Limited
Plot No OZ-14, Hi Tech SEZ,
SIPCOT Industrial Growth Center,
Oragadam, Sriperumbudur Taluk,
Kanchipuram District,
602105 Tamilnadu
Tel: [phone]
Fax: [phone]
[e-mail]
ITALY
Avdel Italia S.r.l.
Viale Lombardia 51/53
20047 Brugherio (MI)
Tel: [phone]
Fax: [phone]
[e-mail]
JAPAN
Infastech Kabushiki Kaisha
Center Minami SKY,
3-1 Chigasaki-Chuo, Tsuzuki-ku,
Yokohama-city,
Kanagawa Prefecture
Japan 224-0032
Tel: [phone]
Fax: [phone]
[e-mail]
MALAYSIA
Infastech (Malaysia) Sdn Bhd
Lot 63, Persiaran Bunga Tanjung1,
SenawangIndustrial Park
70400 Seremban
Negeri Sembilan
Tel:
[phone]
Fax: [phone]
info-m[email protected]
SINGAPORE
Infastech (Singapore) Pte Ltd.
31 Kaki Bukit Road 3
#05-03/06 Techlink
Singapore, 417818
Tel: [phone]
Fax: [phone]
[e-mail]
SOUTH KOREA
Infastech (Korea) Ltd.
212-4, Suyang-Ri,
Silchon-Eup, Kwangju-City,
Kyunggi-Do, Korea, 464-874
Tel: [phone]
Fax: [phone]
[e-mail]
SPAIN
Avdel Spain S.A.
C/ Puerto de la Morcuera, 14
Poligono Industrial Prado Overa
Ctra. de Toledo, km 7,8
28919 Leganés (Madrid)
Tel: [phone]
Fax: [phone]
[e-mail]
TAIWAN
Infastech/Tri-Star Limited
No 269-7, BaodongRd,
Guanmiao Township,
71841 Tainan County,
Taiwan, R.O.C
Tel:
[phone] (ext 201)
Fax: [phone]
[e-mail]
UNITED KINGDOM
Avdel UK Limited
Pacific House
2 Swiftfields
Watchmead Industrial Estate
Welwyn Garden City
Hertfordshire AL7 1LY
Tel: [phone]
Fax: [phone]
[e-mail]
USA
Avdel USA LLC
614 NC Highway 200 South
Stanfield, North Carolina 28163
Tel: [phone]
Fax: [phone]
infoA[email protected]
Manual No. Issue Change Note No. Date
AA 03/008 06-02-03
AB 03/338 06-10-03
AC 07/176 24-05-07
AD 11/082 31/03/11
07900-00683