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17-00001-C WT-4e Op..

1. 135 DOSAD 135 Pare Ust 136 Parts List MAS 350 Bowl Assembly _______ 138 Parts List Upper Tool Holder Assembly ccccccsseccccesececesccceececeecceeeeeeeeeeesencesaeeeensneeees 140 Parts List QUICK Mount 141 Parts List Muti Shuttle 2 143 Parts List HMILArm ASSEM DIY __________ 145 Parte ASSBITIDIV ____ 147 Parts List Vacuum Generator Assembly esses enne 150 Parts List Service Tray Assembly territorio Rea Fasern d Qua pred 151 Parts List Positive Stop System ASSEMDIY cccccssecccsssecccsceceececeeceeseeeeeeseeeeeceseueceeseneeees 152 Parts List Hydraulic Cylinder Main 153 Parts List Electrical Cabinet High Low Voltage 155 Parts List Printed Circuit Board ASSEMDIY ccccesecccssecccsceceescceeeeceeeeneceeeeeseescesseceeseneeees 157 Parts List Hydraulic Reservoir 5 158 Parts List Hydraulic Manifold ASSEMDIY cscccccsssececcesecccecescceseusececseeeceeseneceeesausesetseneees 161
2. 17 00001 C Page 76 MN Haeger wconPonArED A Division of Phillios Corporation Create Better Ideas Name Filter Touch typing e Touch type 440 440 returns all hardware with 440 in the description e Touch on OK o go directly to the desired fastener touch type in the part TR SL 440 1 M station 4 2 Select Fastener station 4 3 Material 4 Select Tooling Type TR SL 440 7 TR 5O 440 4 2 I Stations 2 through 4 are manually operated stations 17 00001 77 I Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Please select the tooling set to use I 2 7 Tooling 2 8 Tooling information 10 00279 Upper Tool Lower wer Tool 10 00279 Verify Tooling Is Correct e Touch on NEXT 64 Touch here to enter of fasteners for STATION 1 65 Touch on 4 for the of fasteners to be inserted 66 17 00001 C ooling 2 8 Tooling Information M Add Insertion Group 2 Amount This screen takes you back to STATION HI to enter the AMOUNT or NUMBER of fasteners to be inserted for this station 9 f oni of Insertions in Group Page 78 MN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas This icon associates a part image with
3. A Division of Phillips Corporation Create Better Ideas 79 2 Amount This screen takes you back to STATION to enter the AMOUNT or NUMBER of fasteners to be inserted for this station Touch here to enter of fasteners for STATION 3 80 9 2 Amount of Insertions in Group Touch on 2 for the of fasteners to be inserted 81 17 00001 C Page 83 I Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Lem This icon associates a part image with the insertion group Select a part image for hardware insertion Touch on IMAGE 82 e Select the same image from e 2 Location I Images can be selected from two different locations Previously Used Images gt Pre Used Saved images previously used e Touch on IMAGE 83 84 17 00001 84 DN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas e 2 Insertion Points in YELLOW Touch on to locate e Use GREEN ARROWS to center points over location 85 86 2 Amount This screen takes you back to STATION to enter the AMOUNT or NUMBER of fasteners to be inserted for this station Touch here to enter of fasteners for STATION 4 87 9 17 00001 85 Nyy Haeger incorrPoratep A Division of Phil
4. 32 Setting the WAC 32 Checking the up travel amp insertion 32 Non conductive mode set up procedure ccsceccsceccccsccccncecccceccccsceccecsceccsceccecececcscesecesees 34 17 00001 C Page 2 DN Haeger Create Better Ideas Getting started Before you turn on the machine 34 thema nile eiecti 34 Checking the Up travel ______ nE ORE 34 SECTION 3 HAEGER SAFETY SYSTEM 36 Safety system CESCLIPTION ccccccsssccccccesecccceescceceesecceeeesececcunecceseneceecsuseceseenecessunceessaenesetsunesss 37 Conductive RID TU 37 Non conductive 37 How the safety WOM eo 37 eee nee eee 39 42 Safety Awareness amp Residual RiSKS sscsccsssscessssesceccececcsccsceccsccscsccsccccscesceccecescescesesceccscs 43 PVT E TERT 43 1 Situations and Actions to 43 2 Residual Safety RISKS 43 Operator Safety Awareness amp Residual Risks ccccsssecccceesecccceesececaesececseeeeceeeeeeceeseuseeeteas 44 Maintenance Safety Awareness amp Residual Risks 46 LEITET 47
5. Stainless Copper vacuum Select Fastener Material e Touch on Steel Tooling 3 Fastener Y 5 Type olup Stroke Mut Standoff eet Blind standot Vibration Time Sec MAS Tras vun Quick Run _ Haeger 1 Station Status BA ES 2 Material 4 Size 5 Insertion Values 7 Quality Current Station TIS prior mus Lon Detall Control Ae Fell mE e Select Fastener e Touch on Stud Pin Stainless Copper _ Vibration cue Brad Standoff stud Pin Blind standoff 17 00001 C Create Better Ideas To program a Quick Run operation you will follow the easy programming wizard using the steps 1 Station Station 1 is a high volume Automatic insertion station working in conjunction with Modular Automated Feed System MAS Stations are Manual tooling Manual feed insertion stations gt gt Steel gt J Stainless gt Copper Atene gt Nut gt Standoff gt Stud Pin gt Blind standoff Page 58 I Haeger Create Better Ideas 2 Material 4 Size 5 Insertion Values 7 Quality Control Gurent Station x 2 Jad Aluminum Stainless Copper 3 Fastener Ty Nut Standoff e Select Fastene
6. Haeger wconPonRATED Create Better Ideas Conductive mode set up procedure continued 4 Examine the insertion Is the hardware properly seated Is the work piece deformed Adjust the insertion force accordingly and insert another fastener 5 Once the hardware is properly inserted start the production run Experienced personnel must test the Safety System at the beginning of each work shift See the Safety System Test in this section of this manual Never attempt to test or demonstrate this machine s Safety System by placing any portion of your hand or body between the Upper and Lower tools Always use the test procedure outlined in Step 3 of this manual Eye protection must be worn when operating this machine 17 00001 C Page 33 Haeger wconPonRATED Create Better Ideas Non conductive mode set up procedure This procedure assumes that you are thoroughly familiar with this machine s controls as described in the first part of this section If you are not familiar with these controls STOP Return to the beginning of this section and review any controls you are not thoroughly familiar with before continuing If you have any questions contact your Haeger Representative Depending on the ambient shop temperature you may need to warm up your Haeger Hardware Insertion Machine before beginning any operations To do this turn it on and let it run for about ten minutes Getting started B
7. The Foot Pedal Switches are used by the operator to control the start of an insertion Main Disconnect Switch This switch controls power for all machine components including the touch screen Rotate clockwise to switch ON and counterclockwise to switch OFF 17 00001 C Page 21 Create Better Ideas Down Up Footswitch The Down Up Footswitch is shielded and connected to the Haeger Hardware Insertion Machine by a heavy duty cable It contains both the Down and Up Footswitches When the Down Footswitch is depressed the Upper Tool Holder moves down If you remove your foot from the Down Footswitch the Upper Tool Holder will stop If you depress the Down Footswitch again the downward motion will start again Conductive Mode e Turn key to the Right Non Conductive Mode UJ Key is removable in this position and should e Turn key to the left not stay with the machine key should be kept by a trained setup person or shop owner In Conductive Mode the Hardware Insertion Machine will complete one normal cycle of the insertion process when the Down Footswitch is depressed and held down Hold the Down Footswitch until the Upper Tool Holder starts to go up again In the Non Conductive Mode when the Down Footswitch is depressed the Hardware Insertion Machine will lower the Upper Tool until it contacts the workpiece and then stop The Down Footswitch mu
8. _ ___ __________________8_ 97 98 Another Setup Stroke Is Required After 99 20 9 mre 102 Station 105 Station 4A 108 SECTION M 112 SECTION 6 MACHINE MAINTENANCE csccsccsccsscsccsccsccsccsccsccsccscsscnscnscnscnscnscnscnscnscnsonsences 113 113 RETRO mI 115 Weekly Care amp Maintenance 124 MAS 350 Care amp 124 PAE e 2 9 125 Upper Tool Changer Care amp Maintenance cccccsccccsseccsesccsececeeseesecteeceeeesseeesensetesesees 126 Upper Tool Holder Care amp Maintenance 127 Diagnostics 2 80 Diagnostics From Main Screen cccscsccecscscscccsccccscscsccccccscncncecsecccscssscesces 128 129 nodo nm 130 Schematics _________ __ 131 US EOP E T _ ____________ _6_ _6______ 132 D 133 E 134 SECHON 7 PARTS LIS
9. 104 136 IN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas A tool in motion e Ready for 3 of 3 insertions Eject Extra Depress footswitch Faritonot Edit Insertion Parameters is now UNLOCKED allowing you to turn it to Station 3 When in the correct position the machine will automatically lock the TIS Turn TIS to STATION 3 Manually place fastener into upper tool I Manually Place Fastener st c3 1 of 3 insertion TT Stroke Saves all the setup points values such as Fastener pick up point vacuum detection length and tooling test e Station 3 tooling and fastener is in place amp ready 9 139 Touch 17 00001 Page 105 DN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Touch on RED SQUARE to begin setup stroke Eject Extra 140 3 Setup Stroke Required A tool in motion Step 1 e Depress Footswitch 9 141 A tool in motion Depress Footswitch again to apply insertion force 17 00001 C Page 106 I Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas A tool in motion Check Part Touch on OK 143
10. outputa machen Digital Outputs DOxx These are Outputs from the PLC to various points on the board to control Relays Air Cylinders Modular Auto Feed MAS and other e Touch on functions DIAGNOSTICS Analog Inputs Alxx These are inputs for the PLC from various sensors in the electrical board such as the Ram Pressure Ram Position and Vacuum Sensor 158 Analog Outputs AOxx These are Outputs from the PLC to various points on the board to control the Ram Force and the MAS Vibration Note Your Machines PLC Version number will be requested by customer service to trouble shoot any field issues XX X X XX Digital Analog Digital Inputs Digital Outputs Analog Inputs DIO Power On DOD Start Light AID Ram Pressure V 0 0085 DI1 Safety Switch 1 DO1 Stop Light counts 4 012 Safety Switch 2 DO2 Buzzer 013 Non Conductive Key 003 Non Conductive Mode Al2 Vacuum Sensor 0 9015 014 Tool Contact 1 L DO4 Vacuum 12 counts 370 015 Tool Contact 2 005 Blowoff 016 DOB MAS Bowl On 0 Al4 Ram Position V 84167 017 Auto Cycle L DO7 Spare 14 counts 3446 018 Footswitch UP 008 Ram UP 019 Footswitch DOS Ram DOWN Analog Outputs DI10 Spare 0010 Bypass Valve L AOD Ram Force A 0 DI11 TIS Sensor 1 0011 MAS Eject 0112 15 2 0012 MAS Blowoff 0 DI13 TIS Sensor 3 DO13 T
11. 1 2009 ISO 13849 1 2008 17 00001 C Page 8 DN Haeger Create Better Ideas Statement of Foreseen Use The WindowTouch 4e insertion machines are intended for use in an indoor commercial or industrial environment Factory authorized training is made available for operators at the time of installation The Insertion Logic technology and Haeger machines are designed to operate at voltages ranging between 208 575V and at 50 60Hz with no additional power requirements Haeger systems do not produce thermal biological fire or radiation hazards etc Again Haeger machines are not intended or designed to be used in hazardous or explosive environments exposure to outside elements of weather such as freezing wet extreme high temperatures or extreme dusty environments See your local representative or visit http haeger com for more details Safety Information also see section 3 This manual contains details on safety when using your new machine Also where applicable cautions and warnings are used throughout this manual to draw your attention to safety precautions The Haeger Safety System section of this manual explains the safety features built into the machine that minimizes the dangers of pinching or crushing while operating the machine 9 It is recommended that in addition the safety details this Haeger insertion machine manual all customers create implement and maintain their own individual sa
12. 15 01667 15 01668 15 01669 15 01674 15 01675 15 01677 15 01678 15 01681 15 01705 15 02063 15 02262 15 02493 15 02562 DESCRIPTION SHCS M3 x 0 5 x 14MM STAINLESS VINYL CAP BLUE VINYL CAP GREEN VINYL CAP RED VINYL CAP YELLOW COVER BASE TIS 2 HUB TIS 2 ROTATION LOWER TOOL ARM TIS 2 BASE COVER ELECTRICAL TIS 2 COVER LOWER TOOL ARM TIS 2 LOCKING PIN ROTATION TIS 2 AXLE TIS 2 ROTATION AUTOMATIC ARM LOWER TOOL TIS 2 SHCS M4 x 0 7 x 8mm BLACK OXIDE STEEL DOWEL PIN 3 16 x 1 2 HARDENED STEEL NEEDLE BEARING 1 SHCS M3 x 0 5 x 25 STEEL BLACK OXIDE 5 M10X1 5X25MM STEEL ZINC PLTD 8 8 BEARING WASHER M10 NEEDLE BEARING M10 SLEEVING 3 8 ID X 3 BRAIDED POLYWSTER FHCS M5 x 0 8 x 16mm BLACK OXIDE CLASS 10 9 DOWEL PIN 3 16 ID x 1 2 LG ACETAL M2 5 45 X 10MM STEEL SHFS WASHER SERRATED M10 DOWEL PIN 3 16 x 1 4 QTY Page 148 DN Haeger Parts List TIS Assembly cont d Create Better Ideas 27 15 02681 CABLE STRAIN RELIEF INSERT MODULAR 2X6MM 1 28 15 02995 SENSOR UNIT TIS 2 QUICK DISCONNECT WT 4 1 29 H 169 6 WASHER LOWER TOOL HOLDER 1 30 H 2535 QUICK DISCONNECT 1 4 1 31 H 2545 BULKHEAD FEMALE QUICK DISCONNECT 1 4 1 32 H 2610 FITTING TUBE REDUCER 1 4 to 5 32 1 33 H 3738 SHCS M5 x 0 8 x 12mm BLACK OXIDE 4 34 3866 ELBOW 10 32 x 5 32 PLASTIC 1 35 15 02997 BASE TOOL HOLDER TIS 2 QUICK DISCONNECT WT 4 1 36 1
13. 17 00001 C Page 5 DN Haeger Create Better Ideas Parts List Hydraulic Suction Filter Assembly sees 163 Parcs ist Return Fiter EE 164 Parts List Motor Pump ASSEMDIY cccccsssccecesececenececenecceencceteeceseeceeeeeeeenecesaeceseeceneneeees 165 Parts List Hydraulic Cooler 166 DECOMMISSIONING Your 167 824 Window ouch AC Start Stop 1 SS ae 08 17 00001 6 DN Haeger Create Better Ideas SECTION 1 INTRODUCTION Congratulations You are using a genuine Haeger Hardware Insertion Machine the industry standard for dependable fastener insertion Haeger Inc is widely recognized as the industry leader in the development and implementation of innovative self clinching fastener installation technologies For over twenty years Haeger engineers have been designing and building flexible systems for installing practically every kind of self clinching fastener into practically every kind of work piece creating new technologies to help Haeger owners get just about any job done productively and profitably Over the years Haeger s innovative tooling and patented quick change automatic fastener feeding systems have revolutionized the way the world
14. ITEM NO 10 11 12 13 14 15 16 17 18 19 20 21 22 17 00001 C PART NUMBER 15 01157 15 01120 15 01113 15 01140 15 01118 15 01115 15 01197 15 00371 15 00066 15 01133 15 01152 15 01116 15 01117 15 00061 15 01147 15 01141 15 01119 15 03072 15 01112 15 01122 15 01121 H 2011 DESCRIPTION 824 MANIFOLD Valve 4 WAY H CENTER 24 VDC CHECK VALVE T 5A 4 PSI SPRING CXFA XAN CK1 NB COUPLING MP FP 90 4 4 MALE PIPE TO FEMALE PIPE 90 VALVE PROP RELIEF BVPPM22 200 G24 HB4 5 Z11 CHECK VALVE 100PSI 5 SPRG CXFA SHCS M6 x 1 0 x 40mm STAINLESS STEEL LOCK WASHER M6 STEEL 5 8 JIC SAE 12 O RING FITTING STRAIGHT FITTING 1 2 ORB TO 1 2 JIC ADAPTER COUPLING 12 12 MALE BOSS TO MALE JIC Solenoid Valve Normally Open Un loader Solenoid Coil 24VDC DIN CONN FITTING 5 8XJICX5 8 O RING STRAIGHT 90 12 12 MALE BOSS MALE JIC 90 FITTING MALE PIPE FEMALE ORB MP FB 4 6 CHECK VALVE SUN HYDRALICS P N CNCC XAN 080 IN MB FP 90 DEGREE 4 4 VALVE SEQUENCE RELIEF VALVE T 10A 100 3000 PSI TRANSDUCER 0 750 PSI 0 10 VDC SLDPRT GAUGE 3000 PSI HYDRAULIC PRESSURE QTY Page 162 Haeger wconPonRATED Create Better Ideas Parts List Hydraulic Suction Filter Assembly NO PART NUMBER DESCRIPTION QTY 1 15 01180 Fitting JIC MB MJ 16 12 1 2 15 01163 Fitting JIC MB MJ 16 16 1 3 15 00781 Su
15. Machine User does not have access to LOAD a Program Admin Operator must Load it first Then the Machine User can RUN it 1 Select User Administrator Advanced Operator Operator Machine User Technician Select your access level for this example we will select MACHINE USER e Then touch on OK 108 17 00001 C Administrator Administrator Operator Level Machine User Technician Haegar Yes Yes Yes Yes Yes Be B Yes Yes Yes Yes gt Administrator Operator Log in 17 Load Program Close Program Log out Machine User o Log in RUN previously Loaded Program 1 Select User This screen allows you to select from a list of users established in the Admin on the main screen then touch on Manage Users to add remove a user The Administrator Advanced Operator Operator Machine User and Haeger Technician users come pre set in the InsertionLogic software and cannot be deleted It is recommended to use them as a template for adding users For a quick reference on the differences between user and access levels see User level security Nee page 16 of this manual Page 94 Ny wconPonarED A Division of Phillips Corporation Create Better Ideas e Touch Type your password e Touch on OK during User Setup in the L2 the main scre
16. Parts List Printed Circuit Board Assembly 12141516 5 KT T 6 4 9 F10 151 170 HU T9 TIO 185 186 gt F20 F5 A T89 T94 171 180 _ gt 151 7401 DESCRIPTION QTY 1 15 00715 SAFETY RELAY BOARD 1 2 15 00135 RELAY SPDT 5 3 11 00376 FUSE 2 AMP 5 4 15 00152 FUSE 5 AMP 1 5 15 00451 FUSE 0 5 AMP 2 6 15 00129 FUSE 1 AMP 1 7 11 00375 FUSE 4 AMP 1 8 15 00130 FUSE 1 6 AMP 3 9 15 00133 FORCE GUIDED RELAY 24VDC 3N O 1 N C 462 1027 3MOPO 2 10 15 00134 FORCE GUIDED RELAY 6VDC 3 N 0 3 N C 462 1026 2 17 00001 C Page 157 Create Better Ideas Parts List Hydraulic Reservoir Assembly Page 158 17 00001 C DN Haeger Create Better Ideas Parts List Hydraulic Reservoir Assembly cont d ITEM NO 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 17 00001 C PART NUMBER 10 00087 11 00319 15 00226 15 00682 15 00758 15 00782 15 00784 SEE SEE SEE SEE 15 01102 15 01103 15 01106 15 01107 15 01108 15 01114 15 01158 15 01165 15 01183 15 01185 15 01393 15 01469 15 01601 15 02166 H 3596 DESCRIPTION BLACK RUBBER SEAL 3 16 X 1 SHCS M6 x 1 0 x 20MM STAINLESS
17. 17 00001 C Page 112 DN Haeger Create Better Ideas SECTION 6 MACHINE MAINTENANCE This maintenance schedule is applicable for standard machine shop operating conditions When operating under severe conditions such as heavy dust and dirt increase the schedule to reflect such conditions DO NOT lubricate the Upper Tool Holder with any lubricant other than a small amount of lithium grease white Other products may interfere with the Safety System Maintenance Schedule Safety System Upper Ram Perform safety system check procedures using Testing the Safety System Daily Clean HMI Filter Touch Screen Computer Back Blow out Filters with clean air Once a month Upper Tool Holder Upper Ram Inspect Continuity Springs and Pins Once a month Upper Tool Holder See Upper Ram Small amount of lithium grease white Once a month warning above between upper tool holder amp cylinder rod 160 hrs Check this label Upper Tool Holder Upper Ram Daily Replace Risk of Crushing label if peeling or damaged Fan Filters Electrical Cabinet Remove filters and blow out filters with Every 3 Months appear weak 960 hrs 960 hrs Lower Hardware Insertion Remove and replace cartridge Once a year Filter Machine Motor Compartment Haeger Part No 15 00888 2000 hrs Hydraulic Fluid and Lower Hardware Insertion Drain fluid and change suction filters Once every 2 years Suction Filters Machine Motor C
18. 4 MOTOR amp PUMP PANEL BASE WT 4 MANIFOLD PANEL BASE WT 4 BACK HYDRAULICS PANEL BASE WT 4 FRONT HYDRAULICS PANEL BASE WT 4 LEVELING FOOT 16 2 LIFTING STRAP MAINTENANCE COVER CYLINDER PANEL 824 4 OT WT ASSY TIS 3 QUICK DISCONNECT WT4e 824 WT amp 824 UPPER TOOL HOLDER ASSY COMPUTER TOUCH SCREEN ASSY QUICK MOUNT UPPER TOOL WT 4 FRONT COVER CYLINDER WT 4 CYLINDER TOP COVER 4e WT OT QTY Page 137 Haeger wconPonRATED Create Better Ideas Parts List MAS 350 Bowl Assembly 17 00001 C Page 138 DN Haeger Create Better Ideas Parts List MAS 350 Bowl Assembly cont d ITEM NO 10 11 12 13 14 15 16 17 18 17 00001 C PART NUMBER SEE TABLE 15 01702 15 02923 15 02924 15 00273 15 02920 15 02921 15 02922 15 01961 15 02914 H 3711 15 03039 H 3738 11 00495 15 01392 15 00484 H 3899 H 3745 DESCRIPTION BOWL MAS 350 DOWEL PIN 4 10mm HARDENED STEEL BLOCK MOUNTING MAS350 LEVER LOCKING MAS 350 1 4 TUBE STRAIGHT FITTING DOWEL BUSHING 10 MAS 350 WEIGHT COUNTER MAS 350 WIPER M8 M10 NUT MAS 350 DOWEL PIN 3MM x 6MM DOOR GATE MAS 350 O RING 1 2 X 3 8 X 1 16 SCREW M5X0 8 X 10MM THUMB WITH SHOULDER STAINLESS SHCS M5 x 0 8 x 12mm BLACK OXIDE FLAT WASHER M5 STEEL LOCK WASHER M5 STEEL ZINC PLATED SHCS M5 x 0 8 x 20mm STAINLESS ST
19. Energized Electrical Equipment 2 A 10 B C Fire Safety Note All fires are grouped into classes according to the type of materials that are burning The classes of fire for the UK Europe Asia etc are different to those used in the USA and Australia so remember to always read labels carefully and consult a trained fire professional 17 00001 C Page 42 DW Haeger Create Better Ideas Safety Awareness amp Residual Risks Introduction This section contains two sets of principles that must be followed to assure maximum safety when operating your Haeger Hardware Insertion Machine The 1 explains behavior and conduct in an effort to avoid or prevent injury The 2 principle describes the residual risks that are inherent in the operation of the Hardware Insertion Machine These are situations or physical aspects of the machine that may present a potential danger to the operator or machine maintenance person but would compromise the capabilities of the machine if changed Therefore they are pointed out as a precaution the operator and trained maintenance person must be aware of when using the machine 1 Situations and Actions to Avoid The Haeger safety system ensures up to a certain level the discrimination between human body and part to be processed Despite this safety system the safety of the operator still depends from operator appropriate behavior and respect of the procedure Human behavior is still
20. o gt poes NOT Save the program and takes you back to Program Wizard e Touch on NO e Software Saves and takes you back to the MAIN Screen V 17 00001 C Page 91 fy LLIN I DN Haeger wconPonarED Create Better Ideas Run Program Step by Step Demo Make sure that you read and understand all of the descriptions instructions and notes contained in this section Heed all of the Warnings and Cautions in this manual Your safety and productivity depend on it One of the most useful features of InsertionLogic is the ability to store and retrieve programs When you save a program you are saving all the setup values for instance Force Dwell Up Position TPS Fastener Detection Fastener Length and Teach sequences Programs can also contain images which illustrate where fasteners are to be inserted This section provides you the operator with the information that you need to add a gt Program and operate the Haeger 824 WindowTouch 4 safely and productively Machine Controls Control Panel Touch Screen A Emergency Stop USB Port Foot Switches Emergency Stop Conductive Non conductive Switch Machine OFF Switch Machine ON Switch 17 00001 C Page 92 D H GUO Nyy Haeger incorporate Create Better Ideas Read and understand all Warnings and Cautions in this manual and follow the instructions for testing the Safety System in the Safety S
21. Check to see if the green start push button lights up when depressed If the push button lights up but motor will not start manually depress the button on the Mag Starter If the motor starts then go to next step If the motor does not start replace Mag Starter Machine turns Overload relay tripped Reset overload relay If Overload relay trips again check to on but motor insure the correct volts are being supplied to the machine does not Start Check wires going to the motor for any signs of damage or loose connections Inspect connections at motor for tightness and inspect ground terminal for tightness If ok change out motor If not ok fix problem and retest No voltage going to Check for voltage at overload relay If no voltage present on discharge side change out overload relay If voltage is present go to next step Check connections at motor for tightness and check ground screw for tightness If ok check for voltage at motor If ok change out motor If not ok inspect wiring for damage Mag Starter shorted Check to see if the green start push button lights up when depressed If the push button lights up but motor will not start manually depress the button on the Mag Starter If the motor starts then go to next step If the motor does not start replace Mag Starter Check for 24vdc at terminal 14 on the Mag Starter If there is no voltage check F6 fuse for damage If there is 24 vdc go to next step Check for 24vdc
22. Fastener LENE REPE TR 72 Part 72 4 SEEC TOOIIng 73 Program Wizard Manual Station 2 of 4 nennen nnne nns 73 Program Wizard Manual Station 3 of 75 Program Wizard Manual Station 4 of 4 nennen nennen nnns 76 Add Insertion Group Station L ss __ SUP 78 nega 78 acini E 79 HDD 79 POIDS __ _ __ ____ DM PEE 80 Add Insertion Grouw Station 2 81 Add 83 Add Insertion Group Station 4 85 Insertion Group Program Correction Example Station 3 88 Save OI OE aret e uU ____________________ 91 gt Run Program Step by Step DEMO ccccccscsccscsccscsccccsceccecsccccscsccsceccccsceccscsseccncess 92 94 o MEET 95 Production RUN OVErVIEW NR 96 Ban NT 96 e NN TEE T T 96 MAS Tm 96 ________________ ____ 96 17 00001 4 DN Haeger Create Better Ideas P OVEN E E E E E 96 Station 4 Insertion Start PRODUCTION 97
23. LEVEL GAUGE WITHOUT THEMOMETER HHSC M8 X 1 25 X 25mm LONG ZINC PLATED RETURN FILTER ASSEMBLY H S RESERVOIR TOP RESERVOIR WELDMENT 824 HYDRAULIC COOLER ASSEMBLY 824 HYDRAULIC MANIFOLD SUBASSEMBLY 15 00785 824 HYDRAULIC MOTOR amp PUMP ASSEMBLY HYDRAULIC SUCTION FILTER ASSEMBLY HOSE SUCTION 1 X 16 50 LONG HOSE SUCTION 3 4 X 16 50 LONG HOSE RETURN 1 2 X 17 25 LONG HOSE COOLER TO MANIFOLD 3 4 X 13 75 LONG HOSE PRESSURE 3 4 X 30 75 LONG HOSE COOLER TO TANK 3 4 X 37 00 LONG HOSE PRESSURE 5 8 X 32 25 LONG NUT M10 HEX FLANGE FITTING 3 4 MALE PIPE TO 1 5 16 MALE JIC FITTING MJ MP 90 8 12 LOCK WASHER M6 DIN127 ZINC HEX HEAD BOLT M8 X 40mm STEEL M6 WASHER ZINC PLATED DRAIN PLUG O RING BOSS 1 2 FLATWASHER 1 4 QTY 20 20 14 Page 159 DN Haeger Create Better Ideas Parts List Hydraulic Reservoir Assembly cont d 27 H 3600 LOCK WASHER 5 16 6 28 15 02715 CAP FILTER RETURN ASSEMBLY 1 29 15 02714 CAP RING FILTER RETURN ASSEMBLY 1 30 15 00888 FILTER ELEMENT MAIN FILTER RETURN ASSEMBLY 1 31 15 02629 BREATHER ELEMENT FILTER RETURN ASSEMBLY 1 32 15 02537 FLANGE GASKET FILTER RETURN ASSEMBLY 1 17 00001 C Page 160 DN Haeger wconPonarED Create Better Ideas Parts List Hydraulic Manifold Assembly 17 00001 C Page 161 DN Haeger Create Better Ideas Parts List Hydraulic Manifold Assembly cont d
24. Machine setup continued If the machine is equipped with a Modular Autofeed System MAS 3 Air must be connected to the fitting on the black hose which extends down from the bottom of the MAS Connect an air line that is capable of delivering of clean dry air For further instructions reference the Modular Auto Feeder Operation and Maintenance Manual Section of this manual 3 ft min 85 l min 90 psi 620 kPa 2 3 CFM 4 If the machine is not yet filled with oil remove the sides of the machine Fill the machine with AW Exxon Humble Hydraulic H or equivalent premium hydraulic oil Replace the sides when finished Fill the reservoir of the machine with the amount of hydraulic oil listed below Gallons 824 Window Touch 4e I Right and left panels can be removed to access Hydraulics 17 00001 Page 19 Create Better Ideas Main power set up The electrical connections required in this section must be made by a qualified electrician Check to make sure that the electrical power supply for this machine has been disconnected at the supply source before doing any work on the machine s electrical system 1 Check the voltage on the Machine Nameplate located on the rear of the machine s Main Electrical Cabinet see Figure 2 3 QD MAKE SURE the machine s incoming shop voltage is the same as the voltage the machine has been wired for
25. Never attempt to test or demonstrate this machine s Safety System by placing any portion of your hand or body between the Upper and Lower tools Always use the test procedure outlined in Step 3 of this manual Eye protection must be worn when operating this machine 17 00001 C Page 35 Haeger wconPonRATED Create Better Ideas SECTION 3 HAEGER SAFETY SYSTEM Safety precautions and warnings Operate this Haeger Hardware Insertion Machine without Never proper instructions Read and thoroughly understand this manual before attempting to operate this machine Tamper with any part of this machine s electrical system unless Never you are a trained electrician and thoroughly understand this machine s electrical schematic Operate this machine while wearing any metal objects i e Never rings watches bracelets etc that may come into contact with the Upper Tool Lower Tool or work piece Attempt to test or demonstrate this machine s Safety System by placing any portion of your hand or body between the Upper Never and Lower tools Always use the test procedure outlined in Section 4 of this manual Exceed the maximum force of 9 000 pounds on the J Frame and Never the Square Tipped Tool Holder Attempt to run any irregular shaped sheet metal part that could contact the Upper and Lower Tools before these tools insert the Never fastener into the part This applies to both the Conductive and No
26. Q Setup Stroke Saves all the setup values such as Fastener pick up point vacuum detection length and tooling test 1 of 3 insertion int A Setup Stroke Fequined points e Station tooling and fastener is in place amp ready Touch on OK a 17 00001 C Page 102 I Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Touch on RED SQUARE to begin setup stroke Extra Setup Stroke Required Press the Down Footswitch oc A tool in motion Depress Footswitch Depress Footswitch quired y Upper tool in motion again to apply insertion force 17 00001 C Page 103 IN Haeger wconPonArED A Division of Phillips Corporation Create Better Ideas A tool in motion Check Part Touch on OK 134 Production Run Program Demo Platel Haeger Program Stats A Bach Sire i YES If adjustments are acceptable bodies 2 I NO If adjustments are NOT acceptable and more adjustments are needed e 151806 Is tho insertion force correct 3 135 Program Stats Sire B ss m INSERTIONS FOR STATION 2 e Ready for 2 insertion nouns 23 Eject Extra 1 Fm timi e Depress footswitch z Edit Insertion Parameters Setup Stroke 9 17 00001
27. Step 1 Safety switch test ProcedUTE sicco isto 47 SECO 2 Conducive Mode Le 49 Step 3 Non conductive mode test ccceesecccssecccescecesceceececeeeecaeecessuecesenecesenscesseecesseeenees 51 SECTION 4 TOUCH SCREEN OPERATION Step by Step Demo 53 Window Touch 4e Introduction 53 Touch Screen Hierarchy OVETVIBME __________ 54 p Quick Run Step by Step Demo senten seruos 56 e 57 Pic c WOT ETT 57 TE 58 E 58 UTER 58 4 Unit amp 51 59 INPUTS Insertion ValuBS 59 REN NOTE 59 SS 60 UD TEINE O 60 MAS 60 PCE NVC Um T 60 VIDON 61 61 IP 61 Tooling Protection System TPS _______________ _ 61 PES CO ON 62 Fastener DO
28. 1 3 15 00117 POSITIVE STOP INNER TUBE 1 4 15 00683 ASSY POSTIVE STOP SLOTTED TUBE 1 5 15 00119 POSITIVE STOP OUTER TUBE 1 6 15 00120 NUT POSITVE STOP 824 WT amp OT 3 1 7 15 00046 CET CONNECTING BAR 1 17 00001 C Page 152 Haeger NconPonRArED Create Better Ideas Parts List Hydraulic Cylinder Main Assembly EDS y p v X z 2 5 5 QE E EE A ACC 2 7 2 Page 153 17 00001 DN Haeger Create Better Ideas Parts List Hydraulic Cylinder Main Assembly cont d ITEM NO PART NUMBER DESCRIPTION QTY 1 15 02889 HYDRAULIC CYLINDER 8 TON WT amp OT 4 1 2 N A POSITIVE STOP SYSTEM ASSEMBLY 1 3 11 00271 824 CYL INSULATION SHOE 1 4 h 3804A 5 8 BOLT INSULATION 2 5 h 3804B 5 8 BOLT INSULATION 2 6 15 00045 824 FRONT J FRAME MOUNT BLOCK 1 7 H 3801 5 8 18 FLANGE NUT 4 8 3802 5 8 HARDENED FLATWAHSER 4 9 H 3803 WASHER INSULATOR 5 8 4 10 15 00295 4 SERV lt VS9 15 01957 632699 1 11 15 02891 ASSY HYDRAULIC TUBE EXTEND 1 12 15 02892 ASSY HYDRAULIC TUBE RETRACT 1 13 15 00040 CET MOUNTING BRACKET 1 14 15 03072 7 16 20 x 1 4 18 90 DEG ELBOW 2 15 15 00291 UPPER TOOL HOLDER ASSEMBLY 1 17 00001 C Page 154 Haeger wconPonRATED Create Better Ideas Parts List Electrical Cabinet High Low Voltage Assembly 17 00001 C Page 155 DN Haeger Create Better Ide
29. If the voltages do not match STOP Contact your Haeger Representative for instructions on how to proceed 2 Ensure that the machine s electrical power supply has been disconnected at the supply source Turn the machine s Main Disconnect Switch to the Off position Using the special key open the door of the Main Electrical Control Cabinet see Figure 2 4 3 Wire the incoming three phase electrical power to the three connectors on the Main Disconnect Switch terminals labeled L1 L2 and L3 Make sure the machine is properly grounded by connecting the incoming ground wire to the top terminal of the green and yellow terminal block on the right side of the Main Disconnect Switch 4 After all electrical connections have been properly made we recommend installing service loops and or an angle bracket not included on the main power cord coming in through the rear of the machine Service loops provide a means of securing the main power cord to the electrical cabinet In addition it provides strain relief and unnecessary wire chafing 5 Close and latch the Main Electrical Control Cabinet door using the special key 6 Install the computer into the front of the computer cabinet and secure with fasteners supplied 3 Open Cabinet 1 Turn Off Power Machine Name Plate 2 Unlock Door Figure 2 4 Figure 2 3 Check the voltage on the Machine 17 00001 C Page 20 DN Haeger Create Better Ideas Machine
30. Machine OFF Switch Machine ON Switch 17 00001 C Page 66 ala Ul PUT CLII 1 Nyy Create Better Ideas Read and understand all Warnings and Cautions in this manual and follow the instructions for testing the Safety System in the Safety System section before attempting to operate this machine NEVER wear anything metallic that may come into contact with the Upper Tool Lower Tool or work piece watches rings bracelets etc Never leave your foot on or above the Down foot switch after you have completed a cycle of the machine Remove it fromthe Down foot switch Keep your feet away from the Down foot switch until your hands are clear of the tooling area and you intend to lower raise the Upper Tool Holder or insert hardware NEVER Operate this Machine without wearing the proper eye protection ei p 32 v Turn on the machine by turning the main disconnect switch to the ON position 33 34 17 00001 C Conductive Mode e Turn key to the Right e UJ Key is removable in this position and should not stay with the machine key should be kept by a trained setup person or shop owner Push Machine ON Switch Page 67 Ny Haeger wconPonArED A Division of Phillips Corporation Create Better Ideas The InsertionLogic banner screen will appear on the computer signifying that th
31. Program Stats 2 2 Step Fastener EI gt NO If adjustments are acceptable and more adjustments are needed 9 yes If adjustments are acceptable M 15 cumani insertion force correct M 144 tool in motion Eject Extra Fantenec e Ready for 2 insertion gt Depress footswitch C 17 00001 C Page 107 I Haeger wconPonarED A nm LJIVISIOI Oj THIS Create Better Ideas tool in motion Marten 0 Production Run Program Demo Plate1 __ Station 3 T Eject Extra Fam timi Edit Insertion xol Parameters Setup Soke ve Aa E 9 is now UNLOCKED allowing you to turn it to When the correct position the machine will 146 Please turn the TIS automatically lock the TIS Select the right color Turn TIS to STATION 4 147 Manually place fastener o into upper tool Manually Place Fastener LEID Setup Stroke Saves all the setup AN Setup Stroke Fequined values such as Fastener pick up point vacuum detection length and tooling test e 1 of 2 insertion points e Station tooling and fastener is in place amp ready Touch on 9 148 17 00001 Page 108 NW Haege
32. Setup Stroke Required Press the Down Footswitch Depress Footswitch 116 Perform setup stroke H Stroke Required Upper tool in motion e Depress Footswitch again to apply insertion force ADJUSTING INSERTION VALUES e Was hardware inserted correctly e Touch on NO 2 B ves Insertion was completed successfully and ready to move on to next insertion point 9 I NO Opens the Adjust Fastener Window Change Insertion and or MAS values to achieve desired insertion production results M 17 00001 C Page 98 DN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Programmed I Fastener Data is displayed as values programmed Insertion Values m Force ENS B3 Flos 25 Adjust Values as A shown Haeger H increase or decreased by touching the B symbols on either insani Van MAS Values side of the value shown Or touch Force Lbs 8 Bec call on the value itself to touch type a new value Check the specifications for your fastener to determine the appropriate force to use p uq Production Run Program Demo Plate Pre am Stals Another setup stroke is required to verify adjustments are acceptable e Run another Setup Stroke with new values RENE 17 00001 C Pa
33. Touch on INSERTION 1 INSERTION 2 98 After Touching on NEW INSERTION 3 this question will popup Add Extra Insertion You already added insertions Do you want to add an exlra mesertion 99 17 00001 89 DN Haeger A Division of Phillips Corporation Create Better Ideas e Missing insertion is now corrected 2 Stals 100 H Station Fasienot Amount 3 2 Step overview Program step 3 e Program Review coun 3 is correct 17 00001 C Page 90 DN Haeger wconPonarED Create Better Ideas Progen Dero 1 Benchmark Proposed Customer Haeger Inc Part Time seconds T SS Machen Window Gch 4 minutes 120 mmn 120 man insertions per hour 540 540 Part Sito used fo calculate benchmark wits r E Medum Lange 4 Progra Dero 1 Benchmark Proposed b ap ar ee Past Ta M B ves saves and then RUNS the WindowToueh 4 minutes 1 20 maj 1 20 min insertions per hour 540 540 program Bert Tisa dened Rum core datari hashes sek i 1 1 Do you want fo start the insertion program after saving Press Cancer to return to the wizard witfiout saving I NO Saves program and takes you back to the Main Screen
34. Type o Shuttle tool is typically setup in station 1 automatic station which works in combination with the MAS bowl 3200 3200 M 2 7 Tooling 2 8 Tooling Information Repeat Wizard to program STATION This time let s select a Steel Captive Nut C 632 2 for our fastener 2 of 4 1 Preset Library gt Global Includes Pre loaded fasteners from different manufactures in software database gt Local User added fasteners to their machine via the ADD NEW FASTENER tab on this screen Page 73 DN Haeger Create Better Ideas Create Insertion Program Wizard Fastener 274 station 2 1 Part Material gt Aluminum Wirid Search How Faster 1 Preset 2 Fastener Manufacturer Steel aptive gt Stainless em Konus gt PSM port Waai 2 Manu acturer Aluminum Blind standoff gt Captive Stee IN t e Select Fastener gt Kerb Konus wee Stainless Touch on CAPTIVE gt PEM Copper 0 Stud Pin PSM e Select Part Material e Touch on the STEEL wand Search Fastonar Jud Wow Fasten 1 Preset 7 Fastener 3 Size Manutacturer T e Select Unit e Touch on UNIFIED e Select Metric Unified Size ID Fastener Type e Touch on NUT PSM Tes Blind standoff Sta
35. Upper Tool Holder and raise it until a positive stop position is reached With a calibrated measuring instrument Digital calipers are best measure the vertical distance between the upper and lower Anvils If this measurement is at least a minimum of 060 in 1 52 mm go to Instruction 5 a If this dimension is less than 060 in 1 52 mm the Safety System has failed Immediately turn the machine off by pressing the red Off Switch and turning the Main Disconnect Switch to the Off position The machine s Main Disconnect Switch must be locked in the Off position until repairs are begun and follow Lock out Tag out procedures Do not operate this machine until qualified personnel have repaired the machine and the Non Conductive Mode has been properly tested 4 e 6 Next keep your hands away from the tooling area Depress the Down Foot pedal switch a second time The machine should exert the pre set 3 000 16 13 Kn force to both upper and lower Anvils and then return to its Up position If this machine completes the above sequence correctly the test of the Safety Switch and Safety System is complete and operating properly 17 00001 C Page 52 f f IN Haeger wconPonarED Create Better Ideas SECTION 4 TOUCH SCREEN OPERATION Step by Step Demo Window Touch 4e Introduction This section provides you the operator with all the information that you need to operate the Haeger 824 WindowTouch 3 safely
36. a yellow run screen Check the pressure reading under the administration change plc values The reading should be no more than 30 at idle Also check the set point to ensure it is at 60 to 90 If the set point is not correct adjust to 90 If there is no pressure being shown at idle Check the wiring and plug going to the pressure transducer for damage or loose connections While watching the pressure screen operate machine and verify the pressure goes above the set point Example If pressure only reaches 60 and set point is at 90 adjust set point to 55 Reset TPS using the part and fastener for the job On older machines set the TPS using min pressure On high speed machines it does not matter what force is selected Check the springs and pins in the upper tool holder for damage or collapsed springs This error will come up when too much information had been entered on any given line or too many characters Example would be TPS setting containing astrics Look for this occurrence on all information windows in the run screen admin screen password screen program screens If you cannot find the problem reload the software and this will reset default values Page 123 DN Haeger wconPonarED Create Better Ideas Weekly Care amp Maintenance This maintenance schedule is applicable for standard machine shop operating conditions When operating in severe conditions such as heavy dust or dirt or 24 hour running Incr
37. gt Never attempt to move the machine with a forklift positioned in front of or on either side of the machine gt Always position the forklift or pallet truck to the rear of the machine when moving the machine with a forklift or pallet truck 7 NEVER lift machine from the FRONT or the SIDE IN OR OUT OF THE BOX MM Position the forklift to REAR of the machine Machine is HEAVY in the REAR and will tilt back when lifted with lift strap 17 00001 C Page 15 I wconPonarED Create Better Ideas Recommended Safe Work Zone It is recommended that prior to delivery the customer layout an area in their facility that allows the operator and maintenance personal ample space to work or service the machine The distances shown below are recommendations It is the customer s responsibility to adjust the Safe Work Zone based on their own individual needs to optimize operator and service technician safety We also recommend that the customer and or operator inform facility visitors of the SAFE WORK ZONE around the machine to minimize or eliminate the possibility of accidental bumping of the operator while the machine is in operation Approximate Machine Foot Print 45 x 65 1 14 m x 1 65 m Service 36 inches 1 0 m min Service 36 inches 1 0 m Service min 36 inches 1 0 m min f
38. important in non conductive mode The safety system may be partly inefficient when machine is used in conductive mode contact of a simple metallic ring on the operator s finger with upper tool may validate the down stroke In short don t get distracted while operating or maintaining the machine always be aware of what you are doing 2 Residual Safety Risks Your Haeger Hardware Insertion Machine is engineered to minimize machine components and operating procedures that may compromise operator safety However in order to maintain some machine operations and functionality certain compromises are required The following table documents some of these residual hazards By making the operator aware of the potential risks we hope to ensure maximum safety in the operation of this machine Attention The photos in the following table illustrate situations that must be avoided when operating your machine 17 00001 C Page 43 iHaet JEF INCORPORATED Div 6 1685 Oral Create Better Ideas Safety Awareness Residual Safety Risks continued Operator Safety Awareness amp Residual Risks Risk of crushing A high risk crushing hazard is created by the Upper Tool and Lower Tooling Safety of the operator in non conductive access operation must remain accessible only to trained and authorized personnel that are experienced in appropriate machinery operating conduct 1 When operating this machin
39. of the analog module and turn Page 118 F4 Fuse blows Short in MAS ly Haeger wconPonRATED Create Better Ideas power back on If Fuse F1 still blows then change out the analog module If F1 fuse does not blow turn off power and check wiring on connector for any shorts to ground Unplug all MAS connectors from the back of the machine at the quick disconnects Insure you reconnect them to the proper location to avoid start up problems Replace fuse and turn power on If fuse still blows go to 5 2 If fuse does not blow then check for a short in one of the MAS and repair as needed Line Filter Shorted Replace Line Filter 5 F21 fuse blows F6 Fuse Blows Fuse F8 blows Safety Switch Fuse F9 blows 6 vdc rectifier shorted 17 00001 C Failed 4 8A power supply F6 ties into a lot of components and is the most difficult to troubleshoot The process of elimination will be used so please follow each step before moving on Mag Starter Green Start Push Button Buzzer in the P C control Cabinet Non conductive Key Switch Safety Switch or the stepper motor for the upper tooling is shorted Relays shorted Change out power supply To isolate which leg is causing the problem pull the following relays from the board R1 R2 R6 K9 AND KS Turn power and see if F6 fuse blows If F6 fuse blows then go to 8 2 If F6 fuse does not blow then go to 8 3 To is
40. operator basic controls All the operator controls are located on the front and right side of machine front cover except the foot pedal this includes the Touch Screen the E Stop button Stop button and Power ON button Touch Screen Control Panel This is the primary interface to the operation control system It is used for most of the machine s settings and functions You will use the touch screen to enter information The screen displays text and graphical information and allows the operator to make selections by touching different parts of the screen as indicated by what is displayed on the screen E Stop Push Button The E Stop Push Button switch is used to shut the machine off in all situations It is a two position switch with a red mushroom button When pushed in it latches turns the machine s controls off and shuts down the machine s motor In the In position the machine cannot be restarted To restart the machine twist the red mushroom button clockwise There is an arrow showing the direction on the mushroom button The mushroom button will snap out and the machine can be restarted Machine Power ON Switch The On Switch is a momentary contact push button switch with a light in it When the On Switch is pushed the machine s controls are turned on and the motor starts The green light in the switch will also turn on When the light is off the machine s controls are off and the motor is stopped
41. shift See the Safety System Test in this section of this manual Depending on the ambient shop temperature you may need to warm up your Haeger Hardware Insertion Machine before beginning any operations To do this turn it on and let it run for about ten minutes 1 Turn the Main Disconnect Switch to the On position The Main Disconnect Switch is located on the upper left and right side of the cylinder cover of the machine 2 Start the machine by pressing the On Switch on the control Panel The green light in the switch will be illuminated and the motor will start If the machine doesn t turn on twist the Off E Stop Switch s clockwise until it pops out and try pressing the On Switch again Using the touch screen controls select the Conductive operation Except for the Down Footswitch and the Off E Stop Switch all the other operating controls referred to in the rest of this procedure are on the Touch Screen Panel The Touch Screen Panel is located on the front of the machine cover 3 Set the machine to Run mode by touching the circle next to the word Run on the screen Set the Up Travel distance to 40 by touching the box containing the Up Travel value and then choosing 30 from the entry screen You can also use the buttons 4 Keep your hands away from the Tool Holder area Use the Footswitches to lower or raise the Upper Tool Holder until it is about 4 in 100 mm above the Lower Tool Holder Remove your foot from the F
42. time of which 2 Material 4 Size 5 Insertion Values 7 Quality your MAS 350 will continue to vibrate Control Station 2 Force Lbs after a fastener has been ejected to the 2 Matic B cow tooling Use the vibration time to adjust pr e Vibration Time Sec the vibration of hardware in the bowl to Copper keep full track of hardware once the Set to 1 0 MAS 350 has stopped vibrating for the Tooling Solup Stoke 9 Stendor MOT The 2 sec value shown is a Blind standoff starting point only Keep good d pats MAS notes for programming production runs later 17 2 Material 4 Size 5 Insertion Values 7 Quality Force Lbs Control Stainless Copper 7 TPS The Tooling Protection System TPS is designed to protect both the tooling and the work piece from damage The TPS can be activated by touching the TPS ON OFF button Nut Standoff Blind standoff Vibration Time 18 L_ T mE F 17 00001 C Page 61 IN Haeger wconPonarED Create Better Ideas HAN 7 Fastener Length This will instruct the machine to perform length 2 Material 4 Size Insertion Values 7 Quality Control Current Station verification of a fastener when the X 2 Force Lbs 3500 fasten
43. 17 00001 C Page 39 DN Haeger wconPonarED Create Better Ideas Lockout Tagout continued InsertionLogic 10 0 0 11 3 4 InsertionLogic Haeger PLEASE POWER DOWN THE MACHINE NOW S It is now safe to tum off your computer 17 00001 C Page 40 DN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Lockout Tagout continued e Main Power Switch e Rotate to OFF Position e Use Finger push to expose holes and insert lock ae WB s e THIS TAG amp LOCK TO BE REMOVED ONLY BY PERSON SHOWN ON BACK e Tagout e DO NOT REMOVE THIS TAG 17 00001 C Page 41 DN Haeger Create Better Ideas Fire Safety Equipment Haeger systems do not produce thermal biological fire or radiation hazards etc however if in the event of a fire having a Multi Class rated fire extinguisher within a reasonable distance of the machine operator s is a sound safety practice and is recommended Your fire extinguisher or fire extinguishers should be able to extinguish fires involving ordinary combustible materials flammable combustible liquids and energized electrical equipment The following is an example of a fire extinguisher with a Multi Class rating Multi Class Rated Fire Extinguisher 2 10 Coverage 2 square meters 10 square feet A Ordinary combustible materials Flammable Combustible Liquids Dry chemical
44. 3200 Stainless Stud Pin 6 Select Tooling T e Select Part 4 e Touch on CFSO 632 10 48 17 00001 C jo __ Create Better Ideas 2 Fastener Type gt Blind Standoff gt Nut gt Standoff gt Stud Pin Metric or Unified Size Identification Select fastener length 5 Part Select part number from database M Page 72 NW Haeger wconPonarED Create Insertion Program Wizard Wizard Search Fasteror Now Fasten 1 Preset 2 Fastener _ Manufacturer 4 Size 2 ea Captive BI Select Tooling Touch on SHUTTLE 505 632 10 CFBSOS 632 10 Stainless Standoff Copper 6 Select Tooling 49 f Pre ain 1 Faries 3 Adding 4 2 8 Tooling information 491 296 Upper Tool H339105 Lower Tool 4 344 216 Shumle 15 01850 Multi Module 255 00 25 Flight Tube 209 296 72 e Verify Tooling Is Correct e Touch on NEXT 50 Create Insertion Program Wizard Fastener 27 e Touch on the WIZZARD Tab Stainless Copper e Touch on GLOBAL p M 3 D 3 4 17 00001 C Station f 7 mnm n A Division of Philljos Corporation Create Better Ideas Tooling
45. 5 03031 AIR CYLINDER SPRING RETURN 12MM BORE 1 37 15 00286 5 32 TUBE POLYURETHANE 0 83 38 15 00285 TUBING 1 4 POLYURETHANE 1 33 39 15 01754 DOWEL PIN 1 4 X 1 2 HARDENED STEEL 2 17 00001 C Page 149 DN Haeger Create Better Ideas Parts List Vacuum Generator Assembly ITEM NO PART NUMBER DESCRIPTION QTY 1 15 02241 VACUUM GENERATOR BRACKET WT 3 amp OT 3 1 2 10 00209 1 8 BRAS CL NIPPLE 2 3 10 00210 BRASS BREATHER 1 8 1 4 10 00211 1 8 BRASS TEE 1 5 11 00587 24V SOLENOID VALVE 1 6 11 00589 VACUUM GENERATOR W 1 7 14 00638 AIR FITTINGS 1 8 15 00890 BHCS M4 x 0 7 x 25mm ZINC PLATED 2 9 15 01325 FITTING BUSHING BRASS 1 4 MALE NPT X 18 FEMALE NPT 1 10 H 5020 SWIVEL ELBOW 90 DEG 1 8 NPT X 1 4 TUBE 1 11 15 02158 Vac Switch ANALOG VDC 1 17 00001 C Page 150 Create Better Ideas Parts List Service Tray Assembly ITEM NO PART NUMBER DESCRIPTION QTY 1 15 01294 Part Bin 7 x 4 Yellow 1 2 15 01291 Part Bin 7 x 4 Dark Blue 2 3 15 01299 Parts Tray Holder 1 4 15 01292 Part Bin 7 x 4 Medium Green 1 5 15 01293 Part Bin 7 x 4 Red 1 6 11 00179 Service Tray Arm 1 7 11 00184 Service Tray Post 1 17 00001 C Page 151 Haeger wconPonRATED Create Better Ideas Parts List Positive Stop System Assembly ITEM NO PART NUMBER DESCRIPTION QTY 1 15 00116 POSITIVE STOP BASE PLATE 1 2 15 00115 POSITIVE STOP CLAMP PLATE
46. BLACK OXIDE NUT HEX M12 X 1 75 THIN STAINLESS QTY Page 142 900000000000000 2 MY N A Create Better Ideas VY 906 OOO00 Parts List Muti Shuttle 2 Assembly Page 143 17 00001 C DN Haeger Create Better Ideas Parts List Muti Shuttle 2 Assembly cont d ITEM NO 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 17 00001 C PART NUMBER 15 01870 15 02883 15 02881 15 02882 3935 15 01754 3871 3815 15 02884 3738 15 01546 15 01974 15 01557 15 01852 3548 3681 15 02057 15 01558 15 01709 15 02513 15 01867 3872 15 02885 15 02789 1 15 02789 15 01804 DESCRIPTION SLIDE TABLE MXS6 MULTISHUTTLE INSULATOR PLATE MULTI SHUTTLE 2 ALIGNMENT PLATE MULTI SHUTTLE 2 MOUNTING PLATE MULTI SHUTTLE 2 FHCS M4 x 0 7 x 12MM BLACK OXIDE DOWEL PIN 1 4 X 1 2 HARDENED STEEL SHSS M5 x 0 7 x 12MM BLACK OXIDE ALLOY STEEL SHCS M6 x 1 0 x 12mm ALIGNMENT TRACK MULTI SHUTTLE 2 SHCS M5 x 0 8 x 12mm BLACK OXIDE TUBE CONN MOUNT MULTISHUTTLE M2 5 45 X 10MM STEEL SHFS MOUNT TUBE CONNECTOR WT amp OT 3 MODULE PLATE MULTISHUTTLE 10 32 1 4 SET SCREW SPRING PLUNGER M5 STEEL FHCS 0 5 x 10mm LID TUBE CONNECTOR WT amp OT 3 FHCS M2 x 0 4 x 4 BLAC
47. Better Ideas Trouble shooting continued Air is not set to 90psi Check the air supply Air blast is wide open Check to ensure the air blast is not full open not allowing not allowing enough enough air to actuate the air cylinder on the singulation air to feed fastener module Singulation module air Check the operation of the air cylinder to ensure there is no cylinder is jammed or binding not working Fastener is jammed Check to ensure the feed hose is not kinked and there are feed hose no fasteners jammed in hose Air Timer Is turned Check the Air timer and the air blast settings to ensure they down to zero are properly set to allow enough time to get fastener down to upper tool Nut is feeding Feed Hose is not Check to ensure the feed hose is turned 180deg from the upside down turned singulation module to the upper tool holder 180deg Incorrect orientation Check to ensure the correct modules are installed for the module or singulation fastener you are running module Ram comes Running non Ensure that you are in the right mode for the material you down and conductive material are running while in the conductive mode taps and then returns up No pressure is built Lower tooling or Check the condition of the lower tooling and the material If material is dirty the material is dirty this will not allow tooling contact to take place continuity Spring and Check the condition of the pins wo
48. DN Haeger wconPonArED A n m A Division of Fhillips Corporation Create Better Ideas 824 WindowTouch4C Operation Manual 17 00001 C Page 1 DN Haeger Create Better Ideas 2012 HAEGER INC rights reserved No part of this work may be reproduced copied adapted or transmitted in any form or by any means without written permission from HAEGER INC HAEGER INC makes no representation or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose Further HAEGER INC reserves the right to revise this publication and to make changes from time to time in the content hereof without obligation to notify any person of such revision or changes Table of Contents SECTION 1 INTRODUC HON 8 7 Congratulations TT 7 Haeger Locations Worldwide cccsscccsssccccseccesecceescccaesececeeeeeeeeesescessuseceseueceseueessencessusecenenees 7 Foreseen USE 9 Safety Information also see section 3 9 Customer Service also see section 6 enne 9 Responsibilities of the ODpOratOL i irrito od rite Enel utu eov hu bet dmt fuc ce tbe dn vultu aae e 9 Responsibilities of the Service TECHNICIAN ccccccccssseccccesscceceeseceeseneecceceeeces
49. EEL FLAT WASHER M4 STEEL BHCS M4 x 0 7 x 8mm STAINLESS STEEL QTY Page 139 DN Haeger wconPonarED Create Better Ideas Parts List Upper Tool Holder Assembly ITEM NO PART NUMBER DESCRIPTION QTY 1 15 00095 BODY 824 WT amp 824 UPPER TOOL HOLDER 1 2 11 00016 CONTINUITY GUIDE PIN 3 3 11 00114 CONTINUITY SPRING 3 4 11 00239 M5 THUMBSCREW ASSEMBLY 1 5 11 00236 STANDARD TOOL ADAPTER 1 6 11 00238 SHSS M5 X 6 BLACK OXIDE 2 7 11 00242 SHSS M6X1 0 X 6 BLACK OXIDE 5 17 00001 C Page 140 Create Better Ideas Parts List Quick Mount Assembly Page 141 17 00001 C DN Haeger Create Better Ideas Parts List Quick Mount Upper Tool Assembly cont d ITEM NO 10 11 12 13 14 17 00001 C PART NUMBER 15 02782 15 01674 15 02790 15 02784 15 02785 H 3738 15 01601 11 00042 11 00319 H 3681 15 41871 15 02786 11 00238 15 03079 DESCRIPTION LOCKING AXLE QUICK M MULTI SHUTTLE WT 4 SHCS M3 x 0 5 x 25 STEEL BLACK OXIDE CONNECTOR MALE 1X AIR amp 3X 24V WT 4 LEG LOCKING SIDE QUICK MOUNT UPPER WT 4 LEG POSITION SIDE QUICK MOUNT UPPER WT 4 SHCS M5 x 0 8 x 12mm BLACK OXIDE M6 WASHER ZINC PLATED LEVER LOCKING SHCS M6 x 1 0 x 20MM STAINLESS SPRING PLUNGER M5 STEEL ASSY MULTI SHUTTLE 2 WT 4 BODY QUICK MOUNT UPPER TOOL WT 4 SHSS M5 X 6
50. ES CEIDDlsoter eene seidondtdsueni od drei 62 62 62 Teo 63 17 00001 Page 3 DN Haeger Create Better Ideas TOONE 63 Modular Auto Feed System 63 ____ 64 O TET 64 Programs Setup Step by Step Demo 66 Joer MG _______________________ 0 68 FAS SN Ol iat ce 68 69 INGO FO m T T UE 69 PROT E P 69 Wis GENTE TR 70 NOE T T 70 Fastener 70 Program Wizard Automatic or Manual Station 1 of 4 71 Nik Uic m 71 Bios 71 Pare NET __ _____ 71 2 US SCN gece ____________ 71 71 TYD Y 72 72 Unto DM UU RN 72
51. Haeger wconPonRATED Create Better Ideas Illistration of safety notes Safety notes are identified by a pictogram and a signal word The signal word describes the severity of the risk at hand Warning possible dangerous situation that could cause minor physical injuries Risk of electrical voltage possible dangerous situation that could cause serious physical injuries Risk of crush injuries possible dangerous situation that could cause serious physical injuries Risk of pinching injuries possible dangerous situation that could cause serious physical injuries Important for a special behaviour or activity for the safe handling of the machinery Application tips and particularly useful information Stop Contact your Haeger Representative for instructions on how to proceed Eye protection must be worn when operating this machine Read First Read instructions first before operating this machine Make sure that you read and understand all of the descriptions instructions and notes contained in this section Follow all of the Warnings and Cautions in this manual Your safety and productivity depend on it The Haeger 824 WindowTouch was designed to conform to applicable ANSI OSHA and CSA safety standards It is the user s responsibility to understand any specific local safety codes that may require additional guarding and conform to those standards 17 00001 C Page 12 MN Haeger wconPonarED A Div
52. IS Lock MAS Vibration 0 0114 Shuttle Retract DO14 Spare 0115 Shuttle Extend 0015 Shuttle Extend 17 00001 Page 129 DN Haeger wconPonarED 4 M 23 f ym meros de S 171 f 2 ivr m yr E A Division of Phillips Corporation Create Better Ideas PLC I O List DIGITAL INPUTS DIO Power On 011 Safety Switch 1 DI2 Safety Switch 2 013 Non Conductive Key DIA Tool Contact 1 015 Tool Contact 2 DI6 Spare DI7 Auto Cycle DI8 Footswitch UP 019 Footswitch DOWN DI10 Spare 0111 TIS Sensor 1 0112 TIS Sensor 2 0113 TIS Sensor 3 DI14 Shuttle Retract DI15 Shuttle Extend Analog Inputs i AEI DIGITAL OUTPUTS DOO Start Light 001 Stop Light DO2 Buzzer DO3 Non Conductive Mode 004 Vacuum DO5 Blow off DO6 MAS Bowl Value DO7 Spare Ram UP DOI Ram DOWN 0010 Bypass Valve DO11 MAS Eject DO12 MAS Blow off DO13 TIS Lock DO14 Spare DO15 Shuttle Extend DI Digital Inputs Ove DO Digital Outputs 2 2 2 2 e 2 e M M Analog INPUTS AIO Ram Pressure AI2 Vacuum Sensor Al4 Ram Position T NE 4 Analog OUTPUTS AOO Ram Force AO6 MAS Vibration ER 17 00001 C Page 130 DN Haeger Create Better Ideas Schematics amp Diagrams Schematics and Diagrams are cust
53. K OXIDE SPRING BLOCK MULTISHUTTLE SHOCK ABSORBER MULTISHUTTLE SHCS M3 x 0 5 x 8MM BLACK OXIDE T BRACKET MULTI SHUTTLE 2 END CAP CONNECTOR MULTI SHUTTLE 2 FEMALE CONNECTOR MULTI SHUTTLE 2 M4 X 18 SHCS QTY Page 144 Haeger Create Better Ideas Parts List HMI Arm Assembly Page 145 17 00001 C DN Haeger Create Better Ideas Parts List HMI Arm Assembly cont d PARTNUMBER DESCRIPTION QTY 1 15 02769 SUB ASSY HMI ARM 1 2 15 02827 USB CONNECTOR W CAP WT amp OT 1 3 H 1071 ELECTRICAL BUZZER 1 4 10 01327 FLAT WASHER 12 ZINC PLATED 4 5 H 3785 LOCKWASHER M12 STEEL ZINC PLATED 4 6 H 3741 SHCS M12 x 1 75 x 50MM STEEL BLACK OXIDE 4 7 15 03065 BUTTON E STOP PUSH 1 8 15 03068 BUTTON RED LED PUSH 1 9 15 03067 BUTTON GREEN LED PUSH 1 10 15 02459 INTERFACE LABEL WT amp OT 4E 1 11 15 03066 SWITCH KEY 1 17 00001 C Page 146 Haeger NconPonRArED Create Better Ideas Parts List TIS Assembly Page 147 17 00001 C DN Haeger Create Better Ideas Parts List TIS Assembly cont d ITEM NO 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 17 00001 C PART NUMBER 15 00449 15 01295 15 01296 15 01297 15 01298 15 01585 15 01586 15 01587 15 01588 15 01589 15 01591 15 01592 15 01596
54. Program Wizard 1 Program Description 1 1 Program Program Demo Plate 1 1 2 Customer Haeger Inc 2 Fastener Differentiation e Select how many different Hardware Trays will be used How many different types of fasteners 1 to 4 are being inserted into this part e Touch on 4 17 00001 C Page 70 e Touch on the WIZZARD Tab Aluminum Steel Stainless e Touch on GLOBAL Copper ea 43 Fepam 1 3 4 wirand Search Fastener Now Fasten 1 Preset 2 Fastener Manufacturer bd Captive Kerb Konus PSM Aluminum Stainless Copper LL e Select Part Material e Touch on the STEEL 44 Create Insertion Program Wizard Search Fastener Fasten 1 Preset 2 Fastener Library x Manufacturer gt Global Captive PEM Select Fastener Manufacturer Aluminum Blind standoff nut e Touch on CAPTIVE Stainless Standa Stud Pin 45 Pregam 2 Fibes 3 Adding mpi 4 e x 17 00001 C NW Haeger wconPonarED Create Better Ideas 1 Preset gt Wizard Tab Typically used to guide you through setup gt Search Fastener Tab Takes you to your list of saved fastener types in both Global and Local databases gt New Fastener Tab Gives the local user the ability to added their own
55. Tools When operating the machine in the Non Conductive Mode be very careful Do not press the Down Footswitch a second time with any portion of your body near the tooling Always wear the proper eye protection when operating this Machine When the Upper Tool Holder moves up 015 in 4 mm to 02 in 5 mm the Safety Switch Actuation Screw actuates the Safety Switch which is mounted in the end of the machine s Cylinder Adapter opening its contacts When the Safety Switch contacts are opened the Upper Tool either returns to the Up position if the machine is in Conductive mode or it stops if it is in Non Conductive mode In operation when the Safety Switch is actuated in Conductive Mode and a non conductive material is between the Upper and Lower Tools the Upper Tool Holder s downward motion is reversed immediately and returns to its Up position If the Safety Switch is actuated and a conductive material is between the Upper and Lower Tools the machine will continue the hardware insertion cycle The machine will apply the set down force to the conductive material between the Upper and Lower Tools and then return to its Up position When the Safety Switch is actuated in the Non Conductive Mode and any material is between the Upper and Lower Tools the Upper Tool Holder stops At this point if the Down Footswitch is depressed a second time the machine will continue the hardware insertion cycle by applying the set down force to the ma
56. am at full up position Foot switch Shorted Check the diagnostic screen under inputs or look at PLC lights inside cabinet and check for X4 to be checked or lighted when the down foot pedal is pressed If the light does not come on then check for24vdc at terminal T 50 to ground If power is present then change out foot switch If power is not present then check Fuse F3 for damage Relays not working Check relays K6 and K9 for proper operation 17 00001 C Page 120 Haeger NconPonRArED Create Better Ideas Trouble shooting continued Problem sowon 16 7 Ramisshortedto 16 7 Check to see if R3 or R6 are activated If these are frame activated and the upper tool is not touching lower tool then you must look for a short from the Ram To Frame Typically this will happen because of a loose guard or one that has some metal showing at or near the top portion of the ram Note The ram must be completely isolated form the frame except for tooling contact Hydraulic leak or Ensure there are no hydraulic leaks at hose connections and broken hose fittings Also check to ensure there is enough hydraulic fluid in the tank 4 way valve sticking Check to see if the light on the down solenoid is coming on when the down footswitch is depressed If the light is coming on manually activate the down solenoid and see if the ram comes down If the ram comes down then change out the 4way valve If the ram
57. ams When you save a program you are saving all the setup values for instance Force Dwell Up Position TPS Fastener Detection Fastener Create new program Length and Teach sequences Programs e Touch on Create New tS can also contain images which illustrate where fasteners to be inserted Q are stored on NS hard drive 38 ie Program Demo Plate 1 n 1 1 Program Name For this example we chose Part ID Program Demo Plate 1 e Touch Type Program Name e x e Program Demo Plate 1 e Touch on OK 39 M A 17 00001 C Page 69 Nyy Haeger incorroratep A Division of Phillips Corporation Create Better Ideas Create Insertion Program Wizard 1 Program Description 1 1 Program Program Demo Plate 1 1 2 Customer inc 1 2 New Customer Haeger Inc e Touch to bring up keyboard e Touch Type Haeger Inc e Touch Ok If customer has already been entered choose Existing to see the list for selection 1 Program Description 1 1 Program Program Demo Plate 1 1 2 Customer Inc Existing New New Customer Mame Ine 1 3 Program Notes 4 Fastener Demo e Touch in Box to enter notes e Touch Type 4 Fastener Demo e Touch OK 41 i Progam 2 Fusbseee 3 Adding 4 Create Insertion
58. and productively Make sure that you read and understand all of the descriptions instructions and notes contained in this section Heed all of the Warnings and Cautions in this manual Your safety and productivity depend on it Machine Controls Control Panel 5 Emergency Stop USB Port Foot Switches Emergency Stop Conductive Non conductive Switch Machine OFF Switch Machine ON Switch Read and understand all Warnings and Cautions in this manual and follow the instructions for testing the Safety System in the Safety System section before attempting to operate this machine NEVER wear anything metallic that may come into contact with the Upper Tool Lower Tool or work piece watches rings bracelets etc Never leave your foot on or above the Down foot switch after you have completed a cycle of the machine Remove it from the Down foot switch Keep your feet away from the Down foot switch until your hands are clear of the tooling area and you intend to lower or raise the Upper Tool Holder or insert hardware NEVER Operate this Machine without wearing the proper eye protection 17 00001 C Page 53 I Haeger wconPonArED A Division of Phillios Corporation Create Better Ideas Touch Screen Hierarchy Overview InsertionLogic 10 0 0 11 QUICK RUN gt Station Program Automatic or Overview Manual Setup Create New Program Start Load Action Edit Sel
59. any irregular shaped sheet metal part that could contact the Upper and Lower Tools before these tools insert the Never fastener into the part This applies to both the Conductive and Non Conductive Modes of operation Press the Down Footswitch a second time in the Non Never Conductive Mode when your hands are in the area of the tooling Operate this Machine without wearing the proper eye Never protection Eye protection must be worn when operating this machine The Safety System s heavy duty retractable electrical cord is very durable however caution should be taken when working close to the edge of deep boxes or cans Operating with the Safety System s electrical cord too close to sharp metal edges may damage the cord Lubricate the Upper Tool Holder with a small amount of lithium white grease Any other lubricant may interfere with the Safety System s operation and will void your machine warrant eoo PPPPPPPP 17 00001 C Page 14 PORATED n 11 I 3 7r Y WHS COrbDora DIVISION y I MA Create Better Ideas SECTION 2 INSTALLATION Handling The Haeger Hardware Insertion Machine is designed to provide the operator with a comfortable working height and to allow freedom of movement when positioning work pieces in the tooling area Because of these features the machine is top heavy when unloading gt Handle with extreme caution
60. arted Before you turn on the machine 1 Determine the installation force required to properly install the hardware you are going to insert Refer to the technical specifications provided by the hardware manufacturer for this insertion force 2 Select the proper tools for this application and install them in the Upper and Lower Tool Holders 1 Have your Supervisor use their access code to set the Conducive Non Conductive mode to the Conductive position Setting the machine 1 Turn the Main Disconnect Switch to the On position 2 Start the machine by pressing the On Switch The green On light in the switch will turn on and the motor will start 3 Verify Run Mode is selected 4 Adjust the Ram up travel control to about 50 up the scale 5 Adjust the Force to the fastener part required force specification Checking the up travel amp insertion 1 Keep your hands away from the tooling area Without positioning the hardware or workpiece for insertion depress the Down Footswitch and complete one stroke of the machine 2 Check the position where the Upper Tool stopped Is it adequate to permit the workpiece to be positioned easily while fasteners are installed If not adjust the Ram Up travel control accordingly If an adjustment is necessary check the new setting by cycling the machine again 3 Keep your hands away from the tooling area Insert the first piece of hardware into the workpiece 17 00001 C Page 32
61. as Parts List Electric High Low Voltage Cabinet Assembly cont d ITEM NO 9H 9L 10 11 12 13H 13L 14 15H 15L 16 17 18 19 20 21 17 00001 C PART NUMBER 15 02734 15 02744 15 02745 15 01719 15 00715 15 02907 15 02773 15 00178 15 03084 15 03083 15 01128 10 01145 15 00137 10 00670 15 00139 15 03064 10 01154 15 00414 15 00219 15 02492 15 01752 15 03092 15 03210 15 03086 DESCRIPTION CABINET ELECTRICAL WT 4 LOW VOLTAGE PANEL ELECTRICAL WT 4 HIGH VOLTAGE PANEL ELECTRICAL WT 4 POWER SUPPLY 120W 5A 24VDC CLEAN SAFETY RELAY BOARD PLC RIO GALIL 47202 CONTROLLER CARD MAS 350 115V 50 60 Hz optional TRANSFORMER 750 VA High Voltage Lenze VFD ABB 5HP 380 480VAC OR Chose High OR Low Voltage Low Voltage Lenze VFD ABB 5HP 200 240VAC part for your machine AMPLIFIER FUSE HOLDER 600V 30A DIN MOUNT CONTACTOR 24 VDC High voltage OVERLOAD RELAY OR Chose High OR Low Voltage Low voltage OVERLOAD RELAY part for your machine EATON AUXILLARY CONTACT 1NO 1NC High Voltage CIRCUIT BREAKER OR Chose High OR Low Voltage Low Voltage CIRCUIT BREAKER part for your machine DISCONNECT SWITCH FAN GUARD 120 MM FAN GROUND STRIP 21 PIN DISCONNECT GUARD INTAKE FILTER EMC Filter 480VAC 16A QTY Page 156 DN Haeger Create Better Ideas
62. at terminal 3 on the Green start push button If there is no voltage check wire from terminal 14 on the Mag starter to terminal 3 on the green start push button for damage If there is voltage go to next step Check for 24vdc at terminal 4 on the green start push button when it is depressed If there is no voltage change out start push button If there is voltage present then check the wire condition from terminal number 4 on the green push button to terminal 13 on the Mag starter for damage Also check the P C fan motor for continuity The fan motor connects to the start push button on terminals X1 positive and X2 negative 17 00001 C Page 116 DW Haeger Create Better Ideas Trouble Shooting continued Source _ Power Supply Shorted Check to ensure 24vdc is coming out of power supply While the meter is still hooked up depress the start button and if voltage drops low 1 7vdc change out power supply Safety relay board Remove wire T 61 from the safety relay board and ensure shorted the wire is not touching anything It will have 24vdc supplied to the wire Try and start machine with T 61 disconnected If machine starts up check all items on that circuit to find what is shorted it the machine does not start up go to step 2 5 Power supply shorted Reconnect wire T 61 and then remove the following wires one at a time and check if machine starts with each wire removed If the machin
63. ction Access Plate 1 4 15 01131 Suction Filter 1 Nut Style 2 5 15 01102 Hose Suction 1 0 x 16 5 1 6 15 01103 Hose Suction 75 x 16 5 1 17 00001 C Page 163 Nyy Create Better Ideas Parts List Return Filter Assembly 15 01114 Hose Cooler to Tank NO PART NUMBER DESCRIPTION QTY 1 15 02715 Cap FilterAssy Return 1 2 15 02714 Ring FilterAssy Return Cap 1 3 15 00888 HydraulicFilter Element 1 4 15 00758 FilterAssembly Return Hycon 1 5 15 01183 Fittting MB MJ 16 12 1 6 15 01114 Hose Cooler to Tank Return 37 1 17 00001 C Page 164 Create Better Ideas Parts List Motor Pump Assembly Parts List Motor Pump Assembly cont d ITEM NO PART NUMBER DESCRIPTION QTY 1 15 01142 90 5 8 3 4 MALE BOSS TO MALE JIC 1 2 15 01127 SPIDER 8240T WT 1 3 15 01126 COUPLER HALF 095 5 8 X 3 16 1 4 15 01125 COUPLER HALF 095 1 1 8 X 1 4 1 5 15 01124 COUPLER 8 5 A PUMP 4 75 LONG 1 6 15 01123 PUMP 824 HS 1 7 15 00077 MOTOR 5 HP 1800 RPM 50 60 HZ 208 440 V 1 8 15 00062 FITTING 5 8XJICX5 8 O RING 90 1 9 15 01143 COUPLER 90 3 4 1 MALE BOSS TO MALE JIC 90 2 For 575 Model machines use part 15 00394 MOTOR 5 HP 575 V in lieu of the MOTOR 5 HP 208 440 V shown above 17 00001 C Page 165 Create Be
64. d applying a force Setting the Up value to Not Applicable MAS 70 100 will cause the Upper Tool to return to the highest point possible 14 HB e e Eject Time sec X e Set to 2 0 N 6 Eject Time Sec The Air Eject Time controls the duration or the blow off Beg EE em time of the air blast which sends the fastener from your MAS 350 to the Tooling desired automatic tooling Use the Eject Timer to adjust the duration of air blast Nut Xu EL CREME H it the fastener does not travel all the way to the tooling increase air ejection 10 time 15 17 00001 Page 60 IN Haeger wconPonarED Create Better Ideas the MAS 350 bowl vibration speed Current Station The bowl s vibration speed controls how fast the hardware travels up ME Clamp the spiral track of the feeder bowl to reach the Module The 50 value shown is a Toon starting point only Experiment HAN 1 6 Vibration Vibration controls e Vibration Set to 25 Stainless Copper with different values to achieve Stroke proper fastener line up at the Standort MOM Door Gate of the MAS 350 bowl Blind standoft e Vibration Time Sec I Keep good notes for HAS 1 0 programming production runs later 16 Time Sec Vibration n controls the duration of
65. d check out our service web page Custom Support service CON VU 17 00001 Page 132 DN Haeger Create Better Ideas SERVICE TEAM Headquarters 811 Wakefield Dr Oakdale CA 95361 Toll Free 800 878 4343 Phone 1 209 848 4000 Fax 1 209 847 6553 Email info haeger com Website www haeger com Haeger Europe Textielstraat 18 7575 CA Oldenzaal The Netherlands Phone 31 6 295 549 27 Fax 31 541 532 400 CHAT LIVE 9AM 3PM Click Here To Chat Live Chat by Live Person 17 00001 C Page 133 DN Haeger Create Better Ideas Warranty Limited Warranty 1 EXCLUSIVE WARRANTY This warranty is exclusive and in lieu of all other express or implied warranties including without limitation the implied warranties or merchantability and fitness for a particular purpose 2 EFFECTIVE DATE The warranty period starts from the date of installation by Distributor or Haeger Factory Technician or from date of receipt if self installed by the customer 3 PRODUCTS As to products any defects in materials will be corrected without charge for parts or labor for a period of one year from warranty effective date Products include the Haeger Insertion Machine Modular Autofeed System MAS and Factory Installed Accessories 4 TOOLING As to tooling any defects in materials or workmanship will be corrected without charge for labor or parts for a period of
66. degrade the fastener s performance and may cause difficulties during the insertion process We also recommend developing a consistent method of handling or holding the part work piece during the insertion process to ensure quality and increase fastener performance long term Self clinching fasteners should be tested to be sure they meet manufacturer s published performance data or specifications specific to the application 17 00001 C Page 10 DN Haeger Create Better Ideas Basic data sheet YOUR Machine Model 824 WindowTouch 4e Serial Number Year Manufactured Voltage Amperes Hertz Machine Hertz MAS Phase 824 WindowTouch 4e Machine Matrix Voltage 208 220 380 480 575 Amperage 17 9 6 6 1 Hertz 50 or 60 50 or 60 50 or 60 Phase 3 3 3 Emissions Noise Sensitivity C weighted pressure level For all locations Noise protection is always recommended Fluids amp Pressure Dimensions Hydraulic Oil AW Exxon Humble Hydraulic Height 90 in 2268 mm ISO Viscosity Width 32 in 813 mm 22 gallons 83 liters 56 in 1422 mm Max Operating Pressure 2 450 psi 169 bar 2900 Ib 1131 kg Equivalent hydraulic oils may be used It is the machine owner s responsibility to determine which hydraulic oils in their area are equivalent to ISO 32 17 00001 C Page 11
67. does not come down check for other hydraulic problems Ram will not Top Of Stroke Setpoint Check the Top Of Stroke set point on the Change PLC Values go up incorrect screen Should be at least 10 numbers below the current value reading with the ram at full up position 17 2 PLC not working 17 2 1 Check for output Y9 on the PLC to see if it is on If not check to see if X4 on the PLC is on when stepping on the up pedal at the foot switch If X4 does not come on check for a shorted foot switch If Y9 on the PLC does come on then go to 17 2 5 Relay burnt Inspect Relay K5 Foot Switch shorted Check the PLC input X5 is coming on when the up pedal is depressed 4 way up solenoid valve Visually check the up solenoid valve on the 4way to see if it not working lights up when the up pedal is pressed If it does light up the manually depress the 4way valve If the ram goes up change out the 4 way valve If there is no light on the up solenoid verify wiring and power going to up solenoid loose wire Verify there is power at T 20 24vdc and then check for power at Solenoid valve If no power at valve but there is power at 20 check for a broken or loose wire not feed Fasteners are jammed Check the orientation module and the singulation module in orientation or to ensure that there are no fasteners jammed in either singulation modules 17 00001 C Page 121 Haeger NconPonRArED Create
68. e material The Upper Tool then returns to its Up position How the safety system works In both Conductive and Non Conductive modes the Safety System relies on the Safety Switch inside the Cylinder Adapter The Upper Tool Holder Retainer Screw secures the Upper Tool Holder to the Cylinder Rod There is a black serrated knob on this Retainer Screw It enables the Upper Tool Holder to move up on the Cylinder Adapter 25 in 6 4 mm To move up the Upper Tool Holder must overcome the light force of the Continuity Springs Guide Pin Tool Holder Retainer L Set Screw Tool Holder Adapter The Safety Switch is inside the Upper Tool Holder 17 00001 C Page 37 Create Better Ideas How the safety system works continued Do not tamper with any part of the Safety System The Haeger Hardware Insertion Machine will not operate properly if any part of the Safety System is removed or damaged The heavy duty retractable Safety Electrical Cord is very durable but caution should be taken when working close to the edges of deep cans Operating with the Safety System Electrical cord too close to sharp metal edges may cut or shear the cord off Test the Safety System every day before you use the machine See the Safety System Test in this section of this manual Never test or demonstrate the Safety System by placing any portion of your body between the Upper and Lower
69. e while wearing any metal objects i e rings watches bracelets etc that may come into contact with the Upper Tool Lower Tool or work piece 2 17 00001 Page 44 iHaet JEF INCORPORATED A Div 4 6 1685 Oral Create Better Ideas Safety Awareness Residual Safety Risks continued Risk of pinching A medium risk pinching hazard is created by the Multi Shuttle moves back and forward exchanging lower tools 3 Risk of pinching A medium risk pinching hazard is created by the Lower Tool rotates for the next station 4 17 00001 C Page 45 Safety Awareness Residual Safety Risks continued Haer JEF INCORPORATED Jn LJ PF d HEHT D I Ne JF 7 Create Better Ideas Maintenance Safety Awareness amp Residual Risks 17 00001 C A Risk of Electrical Shock A high risk electrical shock while working on the RIGHT HALF of the electrical cabinet See Section 7 Electrical Cabinet Assembly to identify High and Low voltage components A Risk of Electrical Shock A high risk electrical shock while working here 47 High Voltage hazard is ALWAYS present in this location until INCOMING MAIN power is shut OFF Page 46 DN Haeger Create Better Ideas Safety System Tests Step 1 Safety switch test procedure Experienced personnel must test the Safety System at the beginning of each work
70. e computer is starting up Once the system environment is fully started the Log In screen will be displayed Operator e Select your access level Machine User for this example we will Haeger Technician select Administrator e Then touch on OK 35 Touch Type your password e Touch on OK 36 17 00001 C 1 Select User This screen allows you to on the main screen then Users touch on Manage Users to add remove a user The Administrator Advanced Operator Operator Machine User and Heager Technician users come pre set in the InsertionLogic software and cannot be deleted It is recommended to use them as a template for adding users For a quick reference on the differences between user and access levels see User level security access page 16 of this manual G User passwords established during User Setup in the We Admin on the main screen then Manage User touch on Manage Users changing user s password touch on Change Parmi one Page 68 I Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas To Program a production operation you will follow the easy programming wizard using the steps 37 Create New One of the most useful features of InsertionLogic is the ability to REFIN store and retrieve progr
71. e does not complete the above sequence correctly check the screen settings If they are not correct reset them and repeat the test If the machine performs correctly go to Instruction 8 7 If the machine does not complete the above sequence correctly there is a failure in the machine s control circuit T a Trained personnel must correct it Immediately turn the machine off by pressing the red Off Switch and turning the Main Disconnect Switch to the Off position The machine s Main Disconnect Switch must be locked in the Off position until repairs are begun and follow Lock out Tag out procedures Do not operate this machine until qualified personnel have repaired the machine and the Conductive Mode has been properly tested 17 00001 C Page 49 DN Haeger Create Better Ideas Step 2 conductive mode test continued 8 Next Place a small non conductive material e g plastic or paper on top of the Lower Anvil making sure the object completely covers the top of the Anvil Keep your hands away from the tooling area Depress and hold the Down Footswitch The Upper Tool Holder should move down the Anvil will contact the non conductive object and without applying the pre set force return to the Up position a This part of Safety System is operating correctly in Conductive Mode After confirming that no force was applied to the non conductive object go to Step 3 Non Conductive Mode Test P
72. e starts with one of these wires disconnected troubleshoot that circuit to find the short T86 T85 T62 T63 T64 T65 T66 T67 Also pull relays R1 R2 R3 R6 6 AND K9 If none of the wires or relays while disconnected allow the machine to start up then change out the safety relay board Problem This next section deals with fuses blowing Typically the problem is with a component shorted to ground The trouble shooting method involves disconnecting wires to isolate components or electrical legs Please follow the procedure outlines and do not skip steps Caution needs to be taken because some wiring may be HOT Ensure you have extra fuses and they are the correct AMP rating as the one currently in use F1 fuse blows PLC Fault or faulty Remove wires T 4 and T 41 from the P C board Restore Clean transformer power and check if F1 fuse blows If it does then change out the Clean 24vdc power supply unit If it does not blow go to next step Reconnect wire 1 4 and restore power If F1 fuse blows then turn off power and reconnect T 41 and go to 3 2 1 If F1 fuse does not blow then reconnect Wire T 4 and go to 3 3 1 E Stop shorted or P C To isolate which leg on the E Stop is shorted you will need to Board Shorted pull the following Fuses F3 F2 and F6 Turn power back on to the machine and if F1 Fuse blows Change out E stop If F1 does not blow Replace Fuse F3 Turn power back on and if F1 Blows then follow t
73. ease the schedule to reflect such conditions MAS 350 Care amp Maintenance T t a e Dirt grease debris builds up over time in the bowl e To avoid getting debris in the bowl lift rather than pour the hardware into the bowl t 1 Remove all fasteners from bowl 2 Use dry compressed air to blow out debris Eye protection must be worn 3 Wipe bowl clean with dry cloth CD If dirt grease is present use with gloves and a clean cloth to wipe off build up A Read all warnings on cleaning solution container amp follow recommendations for safe handling and storage DO NOT use rubbing alcohol WD 40 diesel gas etc to clean MAS 350 composite bowls 17 00001 C Page 124 I Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Flight Tube Care amp Maintenance Dirt grease debris builds up over time in the tubes e t is recommended to blow out flight tube after each tool change e 1 Detach tube s from MAS 350 Module and upper tool changer 4 2 Use dry compressed air to blow out debris C Eye protection must be worn red 3 Rinse inside of tube with Alcoho Denatured Alcohol and air dry Read all warnings on cleaning solution container amp follow recommendations for sa
74. ect power NENNT MEM Using a meter check the volts on the 3 phase disconnect switch inside the electrical cabinet to insure it matches the identification plate on the back of the machine Circuit Breaker Tripped Using a volt meter insure the power coming into the machine is correct You can look at the identification plate on the back of the machine for the correct volt requirements There is a fault with either the motor or the safety board To determine which is at fault disconnect the three wires from the circuit breaker going to the motor and restore power If circuit breaker still trips then go to next step If circuit breaker does not trip inspect motor wiring for damage and check electrical connections at motor including ground wire connection If all wiring is ok and connections are tight change out motor Check volts on discharge side of transformer If not correct change out transformer If correct go to next step Should be 19 VAC Check VDC between terminals T 14 and T 74 and they should read 24VDC If not correct change out Dirty BEN 24VDC power supply If correct go to next step 17 00001 C Page 115 DN Haeger Create Better Ideas Trouble Shooting continued Problem Machine will Circuit Breaker Tripped Check VDC between Terminals T 42 and T 2 and they not turn on should read 24VDC If not correct change out Clean 24vdc power supply
75. ected Program Production Delete 17 00001 C Page 54 DN Haeger Create Better Ideas User level security access User level security access each login account is assigned a security level by an administrator When the machine is first powered On or operator change occurs the user security level must be selected to access the Run or Start Production screen Access amp permissions are as follows Advanced Haeger Administrator Administrator Operator Level Machine User Technician Main Screen Quick Run Yes Yes Yes Yes Run Yes Yes Yes Yes Yes Programs Yes Yes Yes Yes Admin Yes Yes Yes Yes gt gt Quick Setup Stations Yes Yes Yes Yes gt Run Run Programs Yes Yes Yes Yes Yes zz i Programs Filter Yes Yes Yes Select Programs Yes Yes Yes Create New Program Yes Yes Yes Edit Loaded Program Yes Yes Yes Yes Preview Program Yes Yes Yes Start Load Program Yes Yes Yes Yes Edit Selected Program Yes Yes Yes Delete Program Yes Yes Yes 4 Admin Change User s Password Yes Yes Yes Yes View Manage Log Files Yes Change Application Config Yes Yes Open Touch Screen Config Yes Yes Machine Diagnostics Yes Yes Add Remove Users Yes Yes Special Functions Yes Yes 7 5 Shut Down Yes Yes Yes Restart Yes Yes Yes Yes Logoff Yes Yes Yes Yes Yes Ex
76. efore you turn on the machine 1 Determine the installation force that you will need to properly install the hardware you are going to insert Refer to the technical specifications provided by the hardware manufacturer for this insertion force Select the proper tools for this application and install them in the Upper and Lower Tool Holders Have your Supervisor use their access code to set the Conducive Non Conductive mode to the Non Conductive position Setting the machine Turn the Main Disconnect Switch to the On position Start the machine by pressing the On Switch The green On light in the switch will turn on and the motor will start Verify Run Mode is selected Adjust the Ram up travel control to about 50 up the scale Adjust the Force to the fastener part required force specification Checking the up travel amp insertion 1 Keep your hands away from the tooling area Without positioning the hardware work piece for insertion depress the Down Footswitch and complete one stroke of the machine Never leave your foot on or above the Down Footswitchafter you have completed a cycle of the machine Remove it from the Down Footswitch Keep your feet away from the Down Footswitch until your hands are clear of the tooling area 17 00001 C Page 34 DN Haeger wconPoRATED Create Better Ideas Non conductive mode set up procedure continued 2 Keep your hands away from the tooling area Withou
77. en then touch on Manage Manage Users Password User passwords are established Adii ears Users To changing user s Change Password password touch on Change user s password 17 00001 C Page 95 Haeger y y zi lt 9 4 DIVISIO C i hi lOS DOR Production Run Overview Program Action Parts Bice MAS Vibration JF ser Li Estimated time to finish Tuesday May 22 2012 11 01 PM e Touch on PREVIEW Name Program Demo 1 Machine WindowTouch Step Station Tong ncunt e Verify the Program Data is correct for the selected part ready for insertion e Touch on CLOSE 17 00001 C Create Better Ideas Production Run Overview Program Action e Batch Size Is how many parts you must complete Batch quantities can be increased or decreased by touching the B B symbols on either side of the value shown Or touch on the value itself to touch type a new value e Parts Completed A running count of completed parts within a batch e MAS Vibration 96 This feature allows the operator to increase or decrease the vibration intensity of the MAS 350 bowl e MAS Touch 1 to manually vibrate the fasteners up to the MAS doorway ready to for ejection An example of use filling the MAS bowl for t
78. eplace the stop switch If no short is found contact Haeger Service Department Check wiring from the footswitch to the cabinet for damage If wiring appears to be ok go to next step If not ok repair or replace wiring Remove wire from terminal 50 and replace fuse Turn power back on and see if fuse blows If fuse still blows go to 5 2 If fuse does not blow change out the footswitch and reconnect wire to 50 Check wiring on the back of the key switch for tightness or damage If wiring appears to be ok go to next step If problem is found repair as needed Remove wires from terminals 49 and T 67 and replace fuse Turn power back on and if the fuse blows then go to 5 3 If fuse does not blow then replace key switch and reconnect T 49 and T 67 wires Pull relays R1 and R2 and inspect the pins on the back for damage If damage to the pins are found replace the relays If no damage is found go to 5 4 To determine which component is shorted remove the wire terminals 48 analog module T 45 CET and T 46 pressure transducer Restore power and if F1 fuse blows replace or inspect E stop wiring for shorted to frame If fuse does not blow reconnect Wire T 46 and Turn on power If F1 fuse blows change out the pressure transducer If Fuse F1 does not blow reconnect wire T 45 If F1 fuse blows then change out the CET module If Fuse F1 does not blow then reconnect wire T 48 If F1 fuse blows unplug the main connector on the front
79. er contacts the lower tool The TPS Clamp Fastener Length can be activated or deactivated by touching the Fastener Length ON OFF button Stainless _ This feature is particularly helpful with the insertion of studs assuring I Mut e Fastener Length Standoff s on MUS p correct length is being inserted Blind standoff e 5etto jabai Ne This feature is not active when the Tooling selection is set to Manual or Bottom Feed modes 19 Quick Haeger Status EBD 2 Material 5 Insertion Values 7 Quality Control Gurent Station 2 5 0 3500 7 Fastener Detection This will instruct imi rrr ifi etsy 4 the machine to perform detection of Stainless 0 0 asten f het ick Copper size OSEE Vaaia astener at the fastener pickup point 100 of the Shuttle Tooling Jaws The Fastener Fastene S VEN Detection Teog Detection be activated Eject Time Sec deactivated by touching the Fastener Setup Stroke 1 0 Length ON OFF button j Eject Fastener TT This feature is not active when e Fastener Detection the Tooling selection is set to Set to ON Manual or Bottom Feed modes 2 20 2 Material 4 Size 5 Insertion Values 7 Quality Contr
80. er the machine onto the floor 5 Lower the nut on the foot and remove the plate 6 Tighten the foot nut until it is flush with the bottom of the machine s base 17 00001 C Page 17 DN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Machine setup 1 Carefully locate the machine in the shop on a flat and preferably level hard surface such able to with withstand the weight of the machine as described it the Basic Data paragraph of this manual If there is any question on the ability of the sub surface to support the weight of the machine check with a structural engineer As of this publication there are no know requirements for fixing or anchoring the machine to the sub surface check with your local building code official agency or structural engineer in your area to verify 2 Levelit front to back and left to right using the top surface of the Lower Tool Holder as a reference surface see Figure below Using a 7 8 in 22 mm wrench to adjust the feet level the machine left to right and front to back Make sure that all of the machine s feet are securely resting on the shop floor 3 Without changing the height adjustment of the feet tighten the lock nut on each foot using a 15 16 in 24 mm wrench Level the machine by using the Lower Tool Holder as a reference surface 17 00001 C Page 18 inconronsTeD 2d 1 0 Oral Create Better Ideas
81. et Screw located on the right side of the Upper Tool Holder For smaller tools such as the standard Manual Tooling line a Standard Tool Adapter may be installed in the Upper Tool Holder using the same M6 x 6 SHSS The smaller tools are held in the Standard Tool Adapter by another M6 x 6 SHSS also located on the right side of the Standard Tool Adapter When installing any tool or the Standard Tool Adapter always make sure that it is pushed in as far 9 If this thumb screw is lost DO replace it with just any length 5mm screw Using too as possible and is securely held by the M6 screw s long of a screw will damage the safety switch Haeger replacement part numbers 11 00241 THUMB SCREW CAP H 3738 SHCS M5 x 0 8 x 12mm BLACK OXIDE Steps to Install an Upper Tool 1 Loosen the M5 set screw in the Tool Holder or Adapter 2 Insert the tool into the Tool Holder or Adapter 3 Tighten the M6 set screw until the tool is locked securely in place The Safety System s heavy duty retractable electrical cord is very durable however caution should be taken when working close to the edge of deep boxes or cans Operating with the Safety System s electrical cord too close to sharp metal edges may damage the cord 17 00001 C Page 25 Haeger incorporatep Create Better Ideas The Turret Insertion System 1 5 Do not operate the machine without both the Upper and Lower Tools properly locked
82. fasteners LIBRARY gt Global Includes Pre loaded fasteners from different manufactures in software database gt Local User added fasteners to their machine via the ADD NEW FASTENER n on this screen Material gt Aluminum gt Steel gt Stainless gt Copper 2 Manufacturer Captive Kerb Konus PEM PSM will be selecting a Steel Captive Standoff CFSO 632 10 for our Automatic Insertion fastener 1 of 4 Page 71 NW wconPonarED Create Insertion Program Wizard wirand Search Fastener Fasten 2 Fastener 3 Size Manufacturer 1 Preset Library X Global Metric C Local lio Konus Unified PSM T r Blind standoff Standoff Stainless Stud Pin Copper e Select Fastener Type e Touch on STANDOFF 46 MEN 1 Fasbpsas 3 Adding 4 Select Unit of Measure e Touch on UNIFIED Search Ael Fasten 2 Fastener Tee Library Manufacturer Global PEM 1 Preset Stainless Copper e Select Size Identification e Touch on 632 47 e Select Length e Touch on 10 1 98 Global Captive Wm T d cu Loc Kerb Konus Par Local CFSO 632 3200 Psm 308 632 10 3200 Blind standoff Standoff FBSOS 632 10
83. fe handling and storage DO NOT use rubbing alcohol WD 40 diesel gas etc to rinse out inside of flight tubes DO NOT use Silicone Spray as a lubricant on this machine 17 00001 C Page 125 ga Wl A NW Haeger wconPonarED 4 Jl JO OF fi MS LA Mc T Create Better Ideas Upper Tool Changer Care amp Maintenance TE 379 gt e It is recommended to blow out the upper tool changer weekly frequently based on Po usage 2 Use dry compressed air to blow out debris Eye protection must N be worn d DONOT use rubbing alcohol WD 40 diesel gas etc to clean tool changer slides use Silicone Spray as a lubricant this machine 17 00001 C Page 126 f Create Better Ideas Upper Tool Holder Care amp Maintenance p e t is recommended inspect the upper tool use rubbing alcohol WD 40 diesel holder and its contacts 17 00001 C weekly or more frequently based on usage DO NOT use Silicone Spray to lube inside of holder If necessary Alcohol can be applied to a clean cloth to remove dirt and grease gas etc to clean contacts or any part of the holder 1 Turn round thumb screw counter clockwise to allow tool
84. fety codes policies and procedures Customer Service also see section 6 If your machine malfunctions and you are unable to resolve the problem field service technicians can be dispatched to your site to conduct repairs Service visits are paid for by the customer either under a maintenance agreement by purchase order or prepayment Time and material rates are charged for any service not covered under a maintenance agreement Before calling to report a problem gather as much information about the problem as possible and have it ready to provide to your customer care center The more information you can provide initially the more quickly the problem can be corrected Responsibilities of the Operator The machine operator must be properly trained Haeger provides training for the operator in the use of the machine and software at the time of installation It is the customer s responsibility to ensure that only properly trained personnel operate the machine Operators must be fully versed in its operation For any operator unfamiliar with its operation training is required Training is available contact your Haeger representative The customer must also ensure that all operators are aware of the safety issues described in this manual The operator or other trained personnel are expected to handle all user maintenance as detailed in the User Manual If your site has a technician in charge of machine maintenance that person is the optimal candida
85. fi Operator 42 inches 1 067 min RECOMMENDED MINIMUM SAFE WORK ZONE The overall Safe Work Zone Dimensions will vary depending on the size of the part or work piece you are producing It is generally recommended to have 3 1 m to 4 1 22 m minimum safe zone beyond the operator and work piece to maneuver the part into position ready for insertion s In addition the Safe Work Zone provides ample space for the service technician to service the machine 17 00001 C Page 16 Haeger wconPonRATED Create Better Ideas Skid removal The feet are already installed on the machine You will need to lift the machine to remove the skids You will need to open three wrenches to adjust the feet Skid Bolt 9 16 in 13mm socket 9 16 13mm socket wrench Foot 7 8 in 22 mm open end wrench 7 8 in 22 mm 15 16 in 24 mm open end wrench 15 16 in 24 mm 1 Uncrate the machine 2 Remove the 8 lag screws that hold the machine base to the shipping skid 2 on each plate 3 Use the strap on the top of the machine frame and an appropriate sling for the weight of this machine and lift it until it clears the skids The weight of the Haeger Hardware Insertion Machine and skids are as follows Machine Pounds Kiloggram ____ 824 Window Touch 4e 2900 Ib 4315kg 4 Carefully move the machine away from the skids or move the skids Low
86. g continued Fuse F10 6 Vdc rectifier power Change out P C Board blows out being shorted Fuse F20 24 vdc clean power Change out 24vdc clean power supply blows supply shorted Fuse F22 Fan Shorted With Power off Disconnect Wires T 34 and T 33 Turn on Blows power and If F22 Fuse Still Blows Contact Haeger Service If fuse does not blow turn off power and reconnect T 33 Repeat process and turn on power If Fuse F22 Blows change out the fan in the electrical cabinet If fuse F22 does not blow turn off power and reconnect T 34 Turn on power and if fuse blows check e stop for wiring damage or shorts to ground Fuse F23 Proportional Amplifier Change out Proportional Amplifier Blows shorted Filter leaking Filter is dirty Change out filter at seal Check valve in filter Remove filter housing inspect condition of check valve If has came apart damaged replace housing Ram will not Machine not turned Ensure machine is and motor is turning come down on EE ee met Check top of stroke setting under for proper set up CET not working Check to ensure yellow string is connected to top of ram and that there is no slack If slack is present check alignment of CET to top of ram or change out CET unit Top of Stroke set point Check the Top Of Stroke set point on the Change PLC Values incorrect screen Should be at least 10 numbers below the current value reading with the r
87. ge 99 Ny Haeger wconPonArED A Division of Phillips Corporation Create Better Ideas Production Run Program Demo Plate e Touch on the RED SQUARE to begin new setup stroke 122 tool in motion Depress Footswitch Depress Footswitch again to apply A tool in motion insertion force 17 00001 C Page 100 IN Haeger wconPonArED A Division of Phillips Corporation Create Better Ideas A tool in motion p stroke H troke Required Check Part Touch on OK coun INSERTIONS FOR STATION 1 2 Hyves If adjustments are acceptable 2 I NO If adjustments are NOT acceptable and more adjustments are needed Is tho insertion force correct 3 COMPLETE INSERTIONS FOR STATION 1 A tool in motion e Ready for 3 insertion gt Depress footswitch 9 17 00001 101 NW Haeger wconPonarED A Division of Phillios Corporation Create Better Ideas A tool in motion je Machetes Production Run Program Demo Plate1 Station lt Q is now UNLOCKED allowing you to turn it to Station 2 When in the correct position the machine will automatically lock the TIS Turn TIS to STATION 2 129 Manually place fastener into upper tool I Manually Place Fastener
88. he first time qb Verify the Program selected matches the part for insertion and hardware in Stations 1 2 3 amp 4 Touch on PREVIEW to see Tooling hardware insertions per part and a picture of the part Page 96 DN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Production Run Overview Program Overview Program Action BS Era MAS Vibration Programm Mama Program Demo Fite Customor Haeger Program Notes wow c 2i S Li 113 Please turn the TIS Select the right color Turn TIS to Station 1 Station m e Eject or manually place fastener into upper tool t 5 1 of 4 insertion ad Setup Stroke Required points Station 1 tooling and fastener is in place amp ready Touch on OK 115 17 00001 C is UNLOCKED allowing you to turn it to Station 1 When in the correct position the machine will automatically lock the TIS SETUP STROKE REQUIRED 2 I Eject Fastener This feature allows the operator to eject a fastener from the MAS bowl to the automatic tooling system T Setup Stroke Saves all the setup values such as Fastener pick up point vacuum detection length and tooling test Page 97 DN Haeger A Division of Phillips Corporation Create Better Ideas A tool in motion Perform setup stroke
89. he motor has an orange arrow indicating the correct motor rotation Press the On Button The green light in the switch will turn on and the machine s motor will start If the motor turned the same direction as the arrow install the Side Panels on the Machine Base The machine is now ready for use If the motor did not turn in the same direction as the arrow contact your Haeger Representative for instructions Do not operate the machine without both the Upper and Lower Tools properly locked in place with the correct set screws and or Quick Change Lever In this manual the use of the terms left and right refers to the machine operator s left and right when they are standing in front of the machine facing the work area between the Upper Tool Holder and Lower Tool Holder 17 00001 C Page 24 NW Create Better Ideas The Upper Tool Holder The Upper Tool Holder is secured to the machine s cylinder rod by the black serrated knob on its right side You can usually leave this Upper Tool Holder in the machine If you do remove it be very careful There are continuity springs and guide pins inside the Upper Tool Holder These items are very important part of the Haeger Safety System and must not be removed If they are lost do not operate the machine until they have been replaced Large tools such as the One Touch vacuum anvil are secured in the Upper Tool Holder by a M6 x 6 SHSS Socket Head S
90. he procedure for F3 fuse blowing If F1 does not blow replace F2 Fuse If F1 fuse blows then follow the procedure for F2 fuse blowing If fuse does not blow then replace fuse F6 If F1 fuse blows then follow the procedure for F6 Fuse Blowing If none of these solves the problem to a root cause then change out P C Board 17 00001 C Page 117 Trouble continued PLC or ER Module shorted F2 fuse blows Fan m mM Touch screen shorted Stop switch shorted F3 fuse blows Footswitch Shorted Key Switch Shorted E stop Analog Module CET or Pressure transducer shorted mM Relays Shorted 17 00001 C Haeger NconPonRArED Create Better Ideas 3 3 1 Unplug both PLC and Expansion Module power plugs on the bottom of the units and turn on power If Fuse F1 blows then check wiring to both units for shorts to ground If fuse does not blow then reconnect the PLC power plug and turn machine back on If fuse F1 blows change out the PLC If the F1 fuse does not blow then reconnect the power plug for the Expansion Module If the F1 Fuse Blows change out the Expansion Module Check for a short from terminals T 33 and T 25 If no short go to next step If short is found replace fan Unplug touch screen power cord and check for a short If a short is found replace the touch screen If no short is found go to next step Check the stop switch for a short If a short is found r
91. he tooling area Depress the Down Footswitch The Upper Tool Holder should move down the flat Anvils will contact and the Upper Tool Holder should stop immediately If this machine completes the above sequence correctly go to Instruction 4 When operating this Hardware Insertion Machine in the Non Conductive Mode be very careful Do not depress the Down Footswitch a second time after the Upper Tool Holder has stopped on the down stroke with any part of your body near the tooling area If the machine does not complete the above sequence correctly check the touch screen settings If they are not correct reset them and repeat the test If the machine performs correctly go to Instruction 3 If the machine does not complete the above sequence correctly there is a failure in the machine s control circuit and it must be corrected by qualified personnel Immediately turning the machine Off by pressing the red Off Switch and turn the Main Disconnect Switch to the Off position The machine s Main Disconnect Switch must be locked in the Off position until repairs are begun Do not operate this machine until qualified personnel have repaired the machine and the Non Conductive Mode has been properly tested d 4 Remove your foot from the Foot pedal switch box 17 00001 C Page 51 I Haeger incorporatep Create Better Ideas Step 3 Non conductive mode continued 5 Carefully grasp the sides of the
92. holder to slide off 2 Inspect springs and contacts and wipe off with clean dry cloth 3 Wipe off all metallic areas with clean dry cloth 4 Wipe inside of tool holder with clean dry cloth 5 Apply a THIN FILM of t on metallic areas only 6 Re install springs with metal contactors in body of tool holder slide body over sensor and tighten thumb screw Page 127 Haeger iconponaten aum f f f f f Corporati MN Create Better Ideas Diagnostics View infoutputs of The machine Diagnostics From Main Screen 1 Select Usar T Administrator Advanced Operator Operator e Select Administrator e Then touch on OK Machine User Haeger Technician y 156 User Administrator InsertionLogic 10 0 0 11 e Touch on ADMIN 157 17 00001 C Page 128 DN Haeger wconPonarED rY YW fi 4 C ff f M f J VASIL CJ AUI LSU C tL Jl Create Better Ideas Change Password Log Files Edit Configuration Touch Screen Digital Inputs DIxx These are inputs for the Change users password WiewiManage Log Files SET PLC from various points the electrical Diegacstica Manage Users board These Inputs determine what Outputs will be turned on at certain times Adif amose Loser
93. important number on the page It identifies a specific item in Haeger s inventory To avoid delays when ordering parts be very sure the Part Number and Quantity are stated correctly Description This is Haeger s brief description of the part For purchased parts it may also include the manufacturer and their part number Quantity This represents the total quantity of the particular Part which is used in the complete assembly When ordering Parts it may not always be necessary to order the number of parts listed Order only the quantity that is required to make the repairs P 17 00001 C Page 135 DN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas Parts List Main Assembly 3 2 17 00001 Page 136 DN Haeger Create Better Ideas Parts List Main Assembly cont d ITEM NO 10 11 12 13 14 15 16 17 18 19 20 21 17 00001 C PART NUMBER 15 02721 15 02738 15 02734 15 02725 15 02726 15 02736 15 02727 15 02729 15 02728 15 02730 15 02731 15 01160 15 00030 15 03038 15 41593 15 00291 15 03078 15 40017 15 02740 15 03148 824 P STOP DESCRIPTION WELDMENT FRAME WT 4 TOP COVER SHEET METAL WT 4 CABINET ELECTRICAL WT 4 BASE FRAME WT OT 4 MANIFOLD TABLE BASE WT 4 HYDR LINES COVER SHEET METAL WT OT 4 MOTOR amp PUMP TABLE BASE WT
94. in place with the correct set screws and or Quick Change Lever The Lower Tool Holder is secured to the lower arm of the machine s frame by a M16 X 50SHCS Socket Head Cap Screw When this cap screw is loosened the lower tool may be aligned to the upper tool Standard Haeger Lower Tools fit in the Lower Tool Holder without the need for any adapters To loosen or tighten the M16 X 50 SHCS you must turn the turret tool to gain access To align the Turret Tool 1 Bring Upper tool down to just above lower turret with tool installed for alignment 2 Turn the lower turret tool to gain access to the M16 X 50 SHCS 3 Loosen the M16 X 50 SHCS and use the M16 X 60 SHCS on the back of the turret tool to move assembly forward or back 4 Usethe Side adjustment screws to align turret from side to side 5 Once alignment has been set Tighten the Hold down bolt M16 X 50 SHCS To 90 ft Ibs Steps to Install a Lower Tool 1 Turn Turret to allow bolt to be put in under the turret tool arm 2 Place the tool into the Lower Tool Holder 3 Lockthe tool into place in the Lower Tool Holder by tightening the bolt until the tool is locked securely in place 17 00001 C Page 26 INCORPORATED A Jl Ul tF Nilli IS CX 106 Ole T a 4 EA Heu L cy Create Better Ideas Tooling storage The integrated tooling storge cabinet allows for quick and easy accessibilty and quick tool retrieval Tools a
95. inless Copper Standoff Stud Pin e Select Size e Touch on 632 53 iran Search Fastonar Agd How Faster 1 Preset L Fastener _ 5 Fastener x E 2 Global j cartive Metric 4 Length Local Konus PEM PSM Part Matorial ____ 5 Blind standoff Steel Stainless Standoff Copper Stud Pin e Select Length e Select Part Touch on 2 Touch on 632 2 V Doa I HEA o a 54 3 Fh islar 3 E 17 00001 74 Nyy A Division of Phillios Corporation Create Better Ideas Station Wizard Search Fastener New Faster 1 Preset 7 Fastener Library x Manatachurer e Select Tooling Type piia stations 2 through 4 are manually Touch on MANUAL CFAC 632 2 Operated stations 6 Select Tooling Type Steel CFAS 632 2 Stainless gt ee 27 Tooling 28 Tooling information 10 00280 10 00280 Upper Tool Lower Tool 10 00290 2 7 Tooling 2 8 Tooling Information e Verify Tooling Is Correct e Touch on NEXT 56 Repeat Wizard to program STATION 3 This time let s select a Steel Captive Stud e Touch on the CH 632 6 for our fastener 3 of 4 WIZZARD Tab 1 Preset Library gt Global Includes Pre loaded fasteners f
96. ision of Phillios Corporation Create Better Ideas Details of location in the documentation All information in these instructions concerning direction and location refer to the workplace of the Rear side of machine operator In this manual the use of the terms left and right refers to the machine operator s left and right when they are standing in front of the machine facing the work area between the Upper Tool Eye protection must be worn when operating this machine 17 00001 C Page 13 Create Better Ideas Safety precautions and warnings Operate this Haeger Hardware Insertion Machine without Never proper instructions Read and thoroughly understand this manual before attempting to operate this machine Tamper with any part of this machine s electrical system unless Never you are a trained electrician and thoroughly understand this machine s electrical schematic Operate this machine while wearing any metal objects i e Never rings watches bracelets etc that may come into contact with the Upper Tool Lower Tool or work piece Attempt to test or demonstrate this machine s Safety System by placing any portion of your hand or body between the Upper Never and Lower tools Always use the test procedure outlined in Section 4 of this manual Exceed the maximum force of 9 000 pounds on the J Frame and Never the Square Tipped Tool Holder Attempt to run
97. it App Yes 17 00001 C Page 55 NW Haeger wconPonarED d lt f f Create Better Ideas Quick Run Step by Step Demo The 824 WindowTouch 4 Insertion Machine is equipped with a computer running InsertionLogic software This computer controls most of the machine s settings and functions and is equipped with a touch screen You will use the touch screen to enter information into the computer Using the touch screen The touch screen is the main method of entering information into the software and controlling the computer To use a button on the touch screen press firmly on the center of the button 1 V Turn on the machine by turning the main disconnect switch to the ON position E Conductive Mode e Turn key to the Right UJ Key is removable in this position and should not stay with the machine key should be kept by a trained setup person or shop owner Push Machine ON Switch 17 00001 C Page 56 MN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas The InsertionLogic banner screen will appear on the computer signifying that the computer is starting up Once the system environment is fully started the Log In screen will be displayed Userlogin m RO select from a list of users established in the 1 Select User o
98. lips Corporation Create Better Ideas Touch on 2 for the of fasteners to be inserted 2 Amount of Insertions in Group 9 This icon associates part image with the insertion group e Select a part image for hardware insertion Touch on IMAGE e Select the same image from Previously Used Images Location Images can be selected from two different locations Pre Used Saved images previously used e Touch on IMAGE 90 17 00001 C Page 86 DN Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas e 2 Insertion Points in BLUE Touch on to locate e Use GREEN ARROWS to center points over location 17 00001 C Page 87 I Haeger wconPonarED A Division of Phillips Corporation Create Better Ideas 3 1 Add steps __ ____ tation Fastener _ Amount Pete 3 2 Step overview Program step 1 Program Review e OOPS sun 3 should have 3 fasteners we 1 Standoff 4 missed insertion and have to go back and add it 3 1 Add steps 3 2 Step overview Program step e Quickly Double Touch on the picture to re select 1 Standoff 4 image 1 e Touch on IMAGE 96 17 00001 Page 88 NW A Division of Phillips Corporation Create Better Ideas 97 Touch on NEW INSERTION 3 e Touch on e
99. n Conductive Modes of operation Press the Down Footswitch a second time in the Non Never Conductive Mode when your hands are in the area of the tooling Operate this Machine without wearing the proper eye Never protection PPPPPPPP Eye protection must be worn when operating this machine The Safety System s heavy duty retractable electrical cord is very durable however caution should be taken when working close to the edge of deep boxes or cans Operating with the Safety System s electrical cord too close to sharp metal edges may damage the cord Lubricate the Upper Tool Holder with a small amount of lithium white grease Any other lubricant may interfere with the Safety System s operation and will void your machine warrant ooo 17 00001 C Page 36 DN Haeger wconPoRATED Create Better Ideas Safety system description The Haeger Hardware Insertion Machine is equipped with a unique reliable and patented Safety System Conductive Mode When the Safety System detects a non conductive material between the Upper and Lower Tools the Upper Tool s downward motion reverses immediately and returns to its Up position Non conductive mode The Upper Tool s downward motion stops when any material is placed between the Upper and Lower Tools If the Down Footswitch is depressed a second time after the Upper Tool has stopped the machine continues the hardware insertion cycle It applies the machine s set down force to th
100. n the main screen then Manage Users Administrator rrr touch on Manage Users to add reove a user Operator The Administrator Advanced Operator Operator Machine User and Heager Technician users come pre set in the InsertionLogic software and cannot be deleted It is recommended to use them as a template for adding users For a quick reference on the differences between user and access levels see User level security access page 16 of this manual e Select your access level Machine User for this example we will Haeger Technician select Administrator e Then touch on OK erue User passwords are e Touch Type your password established during User Setup in the QU e Touch on OK 4 2 on the main screen then aage ee touch on Manage Users To changing user s password touch o Change Password Change user s password e Touch on Quick Run 17 00001 C Page 57 5 Insertion Values Foros lbs 7 Quality Control i5 Aluminum e Select Station Steel Stainlass i Touch on Station 1 Uic Be 3 Fastener e ir Quick Run Haeger 1 Station Status B 2 Material 4 5 Insertion Values 7 Quality Q Control Current Station X _ gt 8 steel EN
101. ol Cusrent Station K 2 Force Lbs in rs Aluminum Stainless Copper Turret Insertion System TIS This 3 Fastener feature allows for the operator to unlock T M gt Sotup Stroke the TIS allowing it to rotate for the installation and alignment of the Nut SHADE e TIS Turret Insertion System e Set to LOCKED Bind lower tools P 21 17 00001 C Page 62 IN Haeger wconPonarED 5 Insertion Values 7 Quality Force bi Control M UC Dwell ech 5 p 4 Stainless 0 5 Fastener Copper Lip Traeel 3 Length 00 Fastenar 6 MAS Values Eject Time Sec Nut Standoff Vacuum Blind standoff 22 5 Insertion Values 7 Quality Force Lbs Control Stainless Copper _ Lip 38 Fastorar Detection Nut Standoff Tooling Blind standoff e Set to OFF e Set to SHUTTLE 5 EI ye A 23 een Quick Run 2 Material 4 Size 5 Insertion Values 7 Quality e MAS Eorum EFT e Touch on to vibrate fasteners up to position ready to ejected 3 Fastener Type Nut Standoff Blind standoff Vihrabion Time Sec BE 24 17 00001 C Create Bette
102. olate the components to find the cause of the short please follow closely Replace all relays from step 8 1 1 Next remove wires T 63 T 60 T 86 T 62 T 67 amp T 61 Turn on power and if F6 fuse blows then reconnect all the wires back and Change out mag starter If fuse does not blow then reconnect T 15 and turn power back on If fuse F6 blows change out green start push button If the fuse does not blow reconnect wire T 62 If F6 Fuse blows disconnect all MAS plugs at back of machine and reconnect them one at a time with turning the power on and off after each one is connected to find the one causing the outage If the F6 does not blow after wire T 62 is connected reconnect wire T 67 If fuse F6 blows change out the conductive key switch If F6 Fuse does not blow reconnect wire T 86 If F6 fuse blows change out the buzzer inside the P C console If F6 fuse does not blow Reconnect wires T 60 and T 63 If F6 Fuse blows change out the stepper Driver Board Pull Relays R1 R2 R3 K5 K6 K9 Insert one really at a time and turn on power to see if the fuse F6 blows Until you find the relay or path causing the short Then Change out they relay Check to ensure that wire T 3 is connected to the grounding strap on the safety switch Pull fuse F 10 and turn on power If F9 fuse blows change out P C Board or replace the 6 volt rectifier on the board Page 119 Haeger NconPonRArED Create Better Ideas Trouble shootin
103. omized to accurately depict your machine and will not be bound in this operations manual They will be delivered separately on large format paper in an effort make them legible and easy to read Typical Drawing List PLC Schematic Safety Relay Board Internal Schematic Safety Relay Board External Schematic Wiring Schematic Hydraulics Schematic Pnuematic Schematic Electrical Ladder Diagram VVVVVV N 17 00001 C Page 131 y Jl PF D We IT IK D Create Better Ideas Customer Service Keep your machine running Haeger is proud of it reputation for providing you with first class support Our mission is to offer you cutting edge technology machines that will which provide your organization with world class performance and value Contact us today NEED SERVICE A service tech will contact you within 24 hours Call your Haeger Representative our contact information is the front of this manual To save time please be prepared to give your area Haeger Representative the following information Your name Your company s name location and telephone number The Model Number of your Haeger machine The Serial Number of your Haeger machine Avery detailed description of the problem What steps you have already taken to resolve your problem How the machine responded to each of the steps Visit our web site at www haeger com an
104. ompartment located inside the tank Haeger part 15 4000 hrs 01131 Qty 2 refill fluid using AW Exxon Humble Hydraulic H or equivalent ap Contact your local recycling center or governing agency for proper disposal of the old hydraulic fluid 17 00001 C Page 113 DN Haeger wconPoRATED Create Better Ideas Maintenance Schedule cont d Hydraulic Fluid Equivalent hydraulic oils may be used It is the machine owner s responsibility to determine which hydraulic oils in their area are equivalent to Exxon Humble Hydraulic H AW 32 Lithium Grease Each Haeger machine is shipped with a tube of Lubriplate 630 AA produced by Fiske Brothers Refining Company In Europe Fiske Brothers is represented by Total Deutschland GmbH Capacity Chart Machine Gallons Liters WT 4 22 83 17 00001 C Page 114 Haeger NconPonRArED Create Better Ideas Trouble Shooting Pobem Source Machine will Stop button pushed Rotate Red stop button clockwise not turo This will cause the stop button to unlatch and pop out for the start mode Disconnect switch is in Turn disconnect to the on position on the electrical cabinet the off position on the electrical cabinet Open the cabinet and insure the disconnect switch attachment bar is still connected to the switch inside the cabinet Inspect the condition of the disconnect switch handle for _ 1 ee Inspect to insure machine is plugged in to the corr
105. on of your hand or body between the Upper and Lower tools Always use the test procedure outlined in Step 3 of this manual NEVER Operate this Machine without the proper tooling installed If no material and fastener is used you must use two flat anvils 1 Following the Upper and Lower Tool Installation instructions install the 1 in 25 mm Flat Anvils in both the Upper Tool Holder and the Lower Tool Holder 2 If you have just completed Step 1 Safety Switch Test Procedure a The machine is On and the green light in the On Switch is still illuminated If not return to Step 1 and restart the machine by following Instructions 1 and 2 b The Conductive Non Conductive selection is in the Conductive display If not select the Conductive 3 Set the machine to Setup mode by touching the circle next to the word Setup on the screen 4 Change the machine s force to 3 000 13KN by touching the box next to Force entering 3000 and touching the Enter button You can also use the buttons 5 Raise the Upper Tool Holder about 4 in 100 mm by depressing the Up Footswitch 6 Keep your hands away from the tooling area a Depress the Down Footswitch The Upper Tool Holder should move down the Anvils will contact the machine will apply the set force to the Lower Anvil and the Upper Tool Holder will return to the Up position b If this machine completes the above sequence correctly go to Instruction 8 c If the machin
106. one year from the date of receipt Tooling includes all Automatic Tooling all Standard Manual Tooling and all Special Manufactured Tooling 5 PROCEDURE You the customer must notify Haeger Incorporated promptly of any breach of this Limited Warranty by calling or writing to Haeger Inc Headquarters Haeger Europe 811 Wakefield Drive Textielstraat 18 Oakdale CA 95361 7575 CA Oldenzaal The Netherlands Phone 31 541 530 230 Fax 31 541 532 400 Phone 1 209 848 4000 Fax 1 209 847 6553 Haeger Incorporated at its option may elect to replace or repair the machine or part of the machine either in the field or may direct you to ship it to back freight prepaid 6 LIMITATIONS Haeger Incorporated will not be liable in any event for incidental or consequential damages or for failure due to wear and tear abuse improper operation or maintenance repair or modification by personnel not authorized by Haeger Incorporated or other circumstances beyond the control of Haeger Incorporated 17 00001 C Page 134 DN Haeger Create Better Ideas SECTION 7 PARTS LIST Description The Parts in this section of the manual are listed by Item Number Part Number Description and Quantity ITEM NO PART NUMBER DESCRIPTION QTY XX XXXXX XXXXXXXXXX Item NO D Are depicted with in a circle with an arrow pointing to the specific part or assembly Part Number This is the most
107. ootswitches and keep your feet away from it 5 Carefully grasp the sides of the Upper Tool Holder and push it upwards This upward movement should actuate the Safety Switch and the Upper Tool Holder should move up The movement will continue until the Up timer set by the Up Travel 96 number you enter has timed out Remove your hand from the Upper Tool Holder as soon as the movement starts 6 Ifthe Upper Tool Holder moves up the Safety System Switch is operating Go to Step 2 Conductive Mode Test Procedure 7 Ifthe Upper Tool Holder does not move up the Safety System has failed 4 Immediately turn the machine off by depressing the E Stop button and turning the Main Disconnect Switch to the Off position Contact your Supervisor The machine s Main Disconnect 17 00001 C Page 47 DN Haeger Create Better Ideas Step 1 Safety switch test procedure continued Switch must be locked in the Off position until repairs are begun and follow Lock out Tag out procedures Do not operate this machine until qualified personnel have repaired the machine and the Safety System Switch has been properly tested There are three 3 Steps in this testing procedure Do not skip or ignore any of them 17 00001 C Page 48 Haeger wconPonRATED Create Better Ideas Step 2 conductive mode test Never attempt to test or demonstrate this machine s Safety System by placing any porti
108. operator to either run the MAS 350 at a continuous vibration or an intermittent vibration Continuous vibration is commonly used when running the bowl out of hardware for a tooling change or for those small quantity hardware runs Intermittent vibration is most commonly used for normal insertion applications where you have good quantity of hardware that will keep your multi module full at all times MAS 350 Bowl e Fasteners vibrate up and around the MAS bowl 3 e Automatically lining up the fasteners at the doorway of the multi module MAS 350 Quick Mount Assembly e Airis ejected moving the fastener through the tubing e Positioning the fastener at the quick mount assembly ready for insertion 17 00001 C Page 31 Create Better Ideas Conductive mode set up procedure This procedure assumes that you are thoroughly familiar with this machine s controls as described in the first part of this section If you are not familiar with these controls STOP Return to the beginning of this section and review any controls you are not thoroughly familiar with before continuing If you have any questions contact your Haeger Representative Depending on the ambient shop temperature you may need to warm up your Haeger Hardware Insertion Machine before beginning any operations To do this turn it on and let it run for about ten minutes Getting st
109. otates the same direction as the arrow install the Side Panels on the Machine Base The machine is now ready for use go to the Upper Tool Holder section If the motor did not turn in the same direction as the arrow follow to the next series of steps 17 00001 C Page 23 Create Better Ideas Testing of the electrical set up continued gt NEVER tamper with any part of this machine s electrical system unless you are a trained electrician and thoroughly understand this machine s electrical schematic Check to make sure that the electrical power supply for this machine has been disconnected at the supply source before doing any work on the machine s electrical system Adjusting the Wiring if the Previous Step Failed 1 Zn Disconnect the machine from its electrical power supply at the supply source After disconnecting the machine from its electrical power supply at the supply source turn the machine s Main Disconnect Switch to the Off position Using the special Electrical latch key open the door of the Main Electrical Control Cabinet Reverse the incoming electrical leads on terminals L2 and L3 of the Main Disconnect Switch see electrical schematic Close and latch the door using the special key Turn the machine s Main Disconnect Switch to the On position Have someone watch the motor in the base of the machine when you turn the machine on T
110. ownward motion you remove your foot from the force and complete insertion Down Footswitch the Upper Tool Holder will stop If you depress the Down Footswitch again the downward motion will start again Station Repeat depressing foot switch until run is completed 29 Depress Foot Switch Depress again to exert pre set 30 Close 31 Touch on Close to exit Quick Run 17 00001 C Page 65 Ny Haeger wconPonArED Create Better Ideas 20 Programs Setup Step by Step Demo Make sure that you read and understand all of the descriptions instructions and notes contained in this section Heed all of the Warnings and Cautions in this manual Your safety and productivity depend on it One of the most useful features of InsertionLogic is the ability to store and retrieve programs When you save a program you are saving all the setup values for instance Force Dwell Up Position TPS Fastener Detection Fastener Length and Teach sequences Programs can also contain images which illustrate where fasteners are to be inserted mx This section provides you the operator with the information that you need to add a D Program and operate the Haeger 824 WindowTouch 4 safely and productively Machine Controls Control Panel Touch Screen Emergency Stop USB Port Foot Switches Emergency Stop Conductive Non conductive Switch
111. r wconPonarED A Division of Phillips Corporation Create Better Ideas A tool in motion Production Run Program Demo Plate Touch on RED SQUARE to begin setup stroke 149 A tool in motion Stroke Required Exons xe Down LEONE e Depress Footswitch tool in motion Depress Footswitch again to apply insertion force 17 00001 C Page 109 Nyy Haeger A Division of Phillips Corporation Create Better Ideas 152 4 ves If adjustments are acceptable I NO If adjustments are NOT acceptable and more adjustments are needed 153 A tool in motion Eject Extra Panton Edit Insertion Parameters Setup Stroke 154 V 17 00001 C Page 110 JHaeger Create Better Ideas e Program Ends and returns to Main Screen 17 00001 C Page 111 I Haeger wconPonarED Create Better Ideas SECTION 5 OPTIONS Component Part Description Picture 1 Work Light 15 01801 Perform safety system check procedures using Testing the Safety System 2 Laser Part Provides a highly visible easy to read Locating Light red beam of light over the lower tool to aid the operator in locating holes on larger parts Increases productivity and decreases operator fatigue
112. r Ideas Vacuum This feature allows for the operator to switch ON or OFF the vacuum system during the use of automatic tooling with upper vacuum anvil Se Tooling This feature allows the operator to select the type of tooling to run in the selected station 2 M roo nc Options are Shuttle Manual and Bottom Feed Modular Auto Feed System MAS This feature allows the operator to either run the MAS 350 at a continuous vibration or an intermittent vibration Continuous vibration is commonly used when running the bowl out of hardware for a tooling change or for those small quantity hardware runs Intermittent vibration is most commonly used for normal insertion applications where you have good quantity of hardware that will keep your multi module full at all times Page 63 DN Haeger wconPonarED A Division of Phillios Corporation Create Better Ideas e Eject Fastener e Touch on to position Fastener for insertion oe Eject Fastener This feature allows the Nut operator to eject a fastener from the MAS bowl the automatic tooling system 25 Setup Stroke This feature allows the operator to create a first stroke setup This first stroke setup feature must be completed for each of the tooling stations used in the insertion quick run program to record all applicable value
113. r Unit of Measure e Touch on Metric Blind standoff 10 gt Quick Run _ Status EH I gt Metric 4 Size 5 Insertion Values 7 Quality X ae Control Current Station gt Unified m O 159 Aluminum Stainless e Select Fastener Size Touch 11 5 Force Ibs Is the amount of pounds of Quick R Haeger Ha force that will be applied between the iaoa Upper and Lower Tools during the hardware 1 insertion cycle The force can range from 4 5 5 Insertion Values 7 e Mim 1 000 pounds 4 46KN to 16 000 pounds 71 35 KN The 3300 lbs value displayed is derived from a manufacturers table of values however it can be increased or decreased by touching the B symbols on either side of the value shown Or touch on the value 3300 itself to touch type a new value X 2 Force Lbs Unit 3300 Matric Dy TPS on astonar s pesci ee Stainless Copper e Force 165 e Change default value of 3300 to 3500 e Touch twice to set to 3500 pue Check the specifications for your fastener to determine the appropriate force to use 12 17 00001 Page 59 Ny Haeger wconPonarED Create Better Ideas 1 5 Dwell Sec The Dwell is the length of 17 7 Quality time
114. re now organized that maximizes tool life and prevents lost tooling Separete compartments are shown below Vacuum Anvil Tooling Quick Mounting Tooling 9 DCN Muti Shuttle Tooling 17 00001 C Page 27 Haeger Create Better Ideas Quick mount mutli shuttle The Multi Shuttle is a 1 piece quick mount tooling module with quick release mounting The module has an integrated built electrical air supply connections and adjustable positive locking alginment shuttle into the positive locking holder Step 1 Mount shuttle tooling to the bottom of multi shuttle Step 3 Lock multi shuttle in place 17 00001 C Page 28 DN Haeger wconPonarED Create Better Ideas Quick mount TIS 3 Plug for sensors Air hose connection Aux Air port used for the bottom feed tooling Lower tool positioned at Station EH 17 00001 C Page 29 iIHaeger iconPonRATED A Division of Phillips Corporation Create Better Ideas Quick Mount Auto Tooling Step 1 Place tooling onto the MAS adapter align the module with to the locking and alignment pins Step 2 Ensure the module is seated flush and then push the lever towards the MAS bowl to lock 17 00001 C Page 30 DN Haeger wconPonarED f Create Better Ideas Modular Auto Feed System MAS 350 Modular Auto Feed System MAS This system allows the
115. reen takes you back to STATION to enter the AMOUNT or NUMBER of fasteners to be inserted for this station Touch here to enter of fasteners for STATION 2 M 73 2 Amount of Insertions in Group Touch on 3 for the H of fasteners to be inserted 9 74 This icon associates a part image with the insertion group e Select a part image for hardware insertion Touch on IMAGE 79 17 00001 81 Nyy Haeger incorroratep A Division of Phillips Corporation Create Better Ideas e Select the same image from 1 Location I Images can be selected from two different locations Previously Used Images gt Pre Used Saved images previously used e 3 Insertion Points circled in RED Touch on to locate e Use GREEN ARROWS to center points over location Groupa Insertion Points after touching and locating a point on the screen you have an opportunity to move the point directly over the insertion hole Touch on or touch and hold on the appropriate arrow to center insertion point over the desired insertion hole you want to move point for example insertion point 2 of 3 you must delete the last point 3 using the button before you can reposition point 2 3 indicate insertions for step 1 Select Points 78 17 00001 82 DN Haeger
116. rn continuity springs and pins Also check to ensure the upper tooling is not binding on the shaft Safety switch not Check the condition of the safety switch Bring the ram working down to mid stroke and lift up on the upper tool If the ram does not return up then inspect the safety switch system for damage Machine is sensing Check the pressure transducer for proper operation by pressure being built turning off the machine and checking the pressure reading on the administration screen If pressure shows zero start machine and take reading If pressure rises above 30psi turn off machine and inspect the hydraulic system 17 00001 C Page 122 Trouble ae continued mE Check the condition of the proportional amplifier F10 or F9 Fuses Check condition of fuse are burnt Ram Comes Down builds pressure but will not return Continuously getting TPS errors P C Error codes 17 00001 C Relays R3 or R 6 burnt or not working Machine in set up mode Pressure is not being sensed TPS sensitivity set to low TPS set at high pressure Continuity pins and spring worn causing incorrect set point Numerical overflow error Haeger NconPonRArED Create Better Ideas Check to see if relays are cycling Check contacts for burnt conditions If the contacts appear burnt change out relay Check run screen to ensure it is not in set up mode This can also be determined by
117. rocedure 9 If the force was applied to the non conductive object the Safety System has failed PL a Immediately turn the machine Off by pressing the red Off Switch and turning the Main Disconnect Switch to the Off position The machine s Main Disconnect Switch must be locked in the Off position until repairs are begun and follow Lock out Tag out procedures Do not operate this machine until qualified personnel have repaired the machine and the Conductive Mode has been properly tested 17 00001 C Page 50 Haeger wconPonRATED Create Better Ideas Step 3 Non conductive mode test There are three 3 Steps in this testing procedure Do not skip orignore any of them 2 If you have just completed Step 2 The machine is On and the green light in the On Switch is still illuminated If not return to Step 1 Safety switch test procedure and restart the machine by following Instruction in Steps 1 and 2 The Conductive Non Conductive mode is displayed in the Conductive selection Select Non conductive from the touch screen display Verify Auto Run is selected The machine s Force has been set to deliver 3 000 16 13 Kn If this has been changed repeat the instructions in Step 2 Instruction 4 Verify the 1 in 25 mm Flat Anvils are installed in both the Upper and Lower Tool Holders 3 Turn the Conductive Non Conductive Switch to the Non Conductive position 4 Keep your hands away from t
118. rom different manufactures in software database e Touch on GLOBAL gt Local User added fasteners to their machine via the ADD NEW FASTENER tab on this screen 17 00001 C Page 75 iHaeger LS ud illie A DIVISIO Ul If JS E C 2 fell N Create Better Ideas Repeat Steps to program STATION 3 1 Preset Fastener Size Length Fastener Select Tooling Typer Step through Wizard by touching on the selections shown below Qv Eno pe I Stations 2 through 4 are manually operated stations Select MANUAL X Tooling 58 meme __ nume 49m SINE 27 Tooling r78 ym information e H 103 6L 103 61 Upper Tool Lower Tool H 10 6L 2 7 Tooling 2 8 Tooling Information e Verify Tooling Is Correct e Touch on NEXT M 59 Create Insertion Program Wizard Let s Speed up the programming steps by using SEARCH FASTENER in lieu of the wizard to program STATION mn This time let s select a Steel Captive Nut FASTENER Tab TR SL 440 1 for our fastener 4 of 4 1 Preset Library SINE gt Global Includes Pre loaded fasteners NIAE from different manufactures in software database gt Local User added fasteners to their machine via the ADD NEW FASTENER tab on this screen station 4 Captive Touch on the SEARCH Copper
119. s fabricators and manufacturers install hardware So whenever your operation faces an insertion challenge turn to the manufacturer with the most experience in developing self clinching fastener insertion solutions Turn to Haeger Haeger Locations Worldwide Corporate Headquarters Haeger Europe 811 Wakefield Drive Textielstraat 18 Oakdale California 95361 7575 CA Oldenzaal USA The Netherlands 800 878 4343 Phone 31 541 530 230 209 848 4000 Fax 31 541 532 400 Fax 209 847 6553 17 00001 C Page 7 DN Haeger Create Better Ideas EC DECLARATION OF CONFORMITY Manufacturer amp Address Haeger Inc 811 Wakefield Drive Oakdale California 95361 USA Authorized to Compile Technical File Contact Wouter Kleizen Haeger Europe Textielstraat 18 7575 CA Oldenzaal The Netherlands We declare under our sole responsibility that the product identified as Equipment Name 824 WindowTouch 4e Equipment Description Fastener Hardware Insertion Machine Model 824 4HorL Serial Number 8WTAxxxx To which this declaration relates is in conformity with the following standards Directives 2006 42 EC Machinery Directive 2004 108 EC Electromagnetic Compatibility And conformity to relevant directives standards and or provisions where appropriate EN 349 1993 1 2008 ISO 60204 1 2006 1 2009 ISO 12100 1 2010 EN 982 1996 1 2008 ISO 14121 1 2007 ISO 12100 2 2010 EN 953 1997
120. s required for Automation Such as the Shuttle Set Point Tip Detection Fastener Length and Fastener Detection 26 Setup Stroke Required Press the Down Footswitch Step 1 Fastener pick up point Fastener vacuum detection 1 Fastener Length Detection TN EN Setup Stroke Step 1 Station oolina protechan sa Upper tool will lower and record the information applicable to the fastener being inserted e Setup Stroke Step 1 e Depress the Down Foot Switch A Upper tool in motion 27 17 00001 C Page 64 IN Haeger A Division of Phillips Corporation Create Better Ideas Setup Stroke Step 2 Station Fastener Pickup Point vacuum detection Setup Stroke Required e Setup Stroke Step 2 Length and Tooling Protection have been e Depress the Down Foot Switch Again and recorded foling protection set fwn Footswitch again Step 2 ctia If one or both of these values are set to OFF Setup Stroke will NOT detect those that are OFF Insertion done 28 Setup Stroke Required Step 1 Fastener pick up point Setup Stroke Step 3 Station 1 Fastener insertion complete w Fastener vacuum detaction y Fastener Length Detection w Tooling protection set EN Insertion cone Stations Check part are Manual tooling Manual feed insertion stations thus Setup Stroke applicable A tool in d
121. st then be released When the Down Footswitch is depressed a second time the Hardware Insertion Machine will exert the preset force and then return to its Up position Once the upward travel starts release the Down Footswitch When the Up Footswitch is depressed the Upper Tool Holder moves up If you remove your foot from the Up Footswitch the Upper Tool Holder will stop If you depress the Up Footswitch again the upward motion will start again Make sure you read and understand the Warning and Safety Instructions in the Introduction section of this manual and follow the instructions for testing the Safety System in the Safety System section before attempting to operate this Hardware Insertion Machine NEVER depressthe Down foot switch a second time in Non Conductive Mode when your hands in the tooling area 17 00001 C Page 22 Create Better Ideas Testing of the electrical set up The Machine Setup must be completed before testing the electrical setup 1 Turn the machine s Main Disconnect Switch to the On position 2 Twist the Red Mushroom Button clockwise to unlatch the off switch 3 Have someone watch the motor rotation in the base of the machine the motor has an orange arrow indicating the correct rotation direction Press the On Button The green light in the switch will turn on and the machine s motor will start 4 f the motor r
122. suaecesseeceeeeanseeetes 10 Quality of Parts amp F3Stellel S aient ___ _ EE 10 __6_________________ ME 11 E NOUS GS 12 Details of location in the 13 Safety precautions 14 SECTION 2 INSTALLATION icio 15 15 Recommended Safe Work Zone ccsesccccssssecccceseccecesccecaussececsuseceeeeeecceseeseecessuecesseeeceetenseeeeeas 16 17 o RETE 18 OWS 5 20 Machine operator basic 5 nnne 21 Cb E OUI RUDI staat 23 TOON OO a RR DONT 25 The T rret Insertion 26 TOONE ON Tm 27 TO UAE TUG RENE OT 28 CICER Tao ne TIS 3 ____ ___________ 29 _ Ui tU dT Sa Re 30 Modular Auto Feed System MAS 350 ee enne 31 Conductive mode set up sese sese se 32 Getting started Before you turn on the machine
123. t positioning the hardware or work piece for insertion depress the Down Footswitch The Upper Tool Holder will move down the Upper and Lower Tools will contact and stop Release the Down Footswitch Depress the Down Footswitch a second time The machine will immediately apply the force to the Lower Tool and the Upper Tool will return to the Up position 3 Check the position where the Upper Tool stopped Is it adequate to permit the work piece to be positioned easily while fasteners are installed If not adjust the Ram Up travel control accordingly If an adjustment is necessary check the new setting by cycling the machine again 4 Keep your hands away from the tooling area Insert the first piece of hardware into the work piece 5 Examine the insertion Is the hardware properly seated Is the work piece deformed Adjust the insertion force accordingly and insert another fastener 6 Once the hardware is properly inserted start the production run gt Experienced personnel must test the Safety System at the beginning of each work shift See the Safety System Test in this section of this manual NEVER press the Down Footswitch a second time in Non Conductive Mode when your hands are in the tooling area Never leave your foot on or above the Down Footswitch after you have completed a cycle of the machine Remove it from the Down Footswitch Keep your feet away from the Down Footswitch until your hands are clear of the tooling area
124. te While any trained operator may perform routine maintenance the best maintenance results from familiarity with the machines internal operation and history The machine requires daily maintenance to ensure the highest insertion quality and longer life for the machine The machine design provides you easy access to perform this simple task and it is essential that machine maintenance is performed as described in the Maintenance Schedule section of this manual It is the responsibility of the operator to try to eliminate simple problems before calling a service representative But knowing when to call for 17 00001 C Page 9 DN Haeger Create Better Ideas service is also important An untrained operator must not attempt to service the machine as this may cause further damage When you have determined that a service call is required call as soon as possible See the Troubleshooting and Maintenance sections for more details Responsibilities of the Service Technician Field service technicians must have machine and InsertionLogic service training The service technician is responsible for all repairs upgrading and modification requested by the customer or mandated by the Haeger Service and Support Group The service technician who installs the machine will also provide training for the operator that covers all of the basic skills and safety practices required to operate the machine Service personnel must be furnished wi
125. terial between the Upper and Lower Tools and then return to its Up position 17 00001 C Page 38 I wconPonarED A Division of Phillips Corporation Create Better Ideas Lockout Tagout Lockout tagout LOTO or lock and tag is a safety procedure which is used ensure that malfunctioning machines are properly shut off and not started up again prior to the completion of maintenance or servicing work It requires that hazardous power sources be isolated and rendered before any repair procedure is started Lock and tag works in conjunction with a ock usually locking the device or the power source and placing it in such a position that no hazardous power sources can be turned on The procedure requires that a tag be affixed to the locked device indicating that it should not be turned on Lockout Tagout procedure 1 Select User Administrator Level e Machine User does not have access to Shut Down the machine Operator e Select your access level Machine User for this example we will Haeger Technician select Administrator e Then touch on OK User passwords e Touch Type your password established during User Setup in the NP e Touch on OK on the main screen then Manage Users Apt eere parh touch on Manage Users changing user s password touch Change Password Change user s password
126. th proper tools for the installation and maintenance of the machine Quality of Parts amp Fasteners The WindowTouch 4e is designed and engineered for high volume installation of self clinching fasteners of all types and sizes As a rule the quality of parts and fasteners is very important to getting the most out of your WindowTouch 4e machine The next two paragraphs are general in nature but critical to maximizing productivity quality and profit potential Fastener Quality Basics In general self clinching fasteners are designed with an annular recess in the shank that allows the softer metal of your part work piece to cold form in and around it and permanently lock the fastener in place Inspecting the fasteners on a regular basis and verifying they are constructed with in design tolerances is very important With studs and stand offs this is especially critical as they increase in length We highly recommend coordination between yourself and the fastener supplier to determine the acceptable dimensional tolerances and force requirements for your particular application in an effort to achieve consistent quality Part Quality Basics Take special care in inspecting all parts in which the fasteners will be inserted Verify the holes in the part meet the required specifications and tolerances In addition visually inspect each part looking for burrs and irregularities around each hole Holes out of tolerance burrs and irregularities will
127. that the force is applied between eG Control Current Station the Upper and Lower Tools It can range 3500 from 0 0 seconds to 3 0 seconds If you Aluminum Dwell Sec Clamp set the Dwell to 0 0 seconds the Upper Tool will lower apply the Force and immediately return to the Up position If you set the Dwell value greater than 0 0 seconds the Upper Tool will lower and continue applying the force for the length of time set here Stainless Copper 3 Fastener TRO Type Mut Standoff e Dwell Sec e Setto 0 5 Ban increased Dwell setting should be used when inserting fasteners into such as Stainless steel 13 2 Material 4 5 5 Insertion Values 7 Quality Control Current Station 5 Up Travel Not Applicable here X TUN 2 3500 The Up Travel value controls the Up Dwel Se position of the Upper Tool This is the Stainless 05 position the upper tool returns to after copper En Up Travai m on applying the force The Up value is 100 Fastener measured as percentage of the total cylinder stroke It will vary depending Setup Stroke the size of the Upper and Lower Tools If Nut the Up value is set to 096 the Upper Tool Sus Up Travel 9 Eject Fastener will to its height after Blin
128. the insertion group e Select a part image for hardware insertion Touch on IMAGE 67 Touch on part image 1 Location I Images can be selected from two different locations gt USB Typically used to pull in images from a camera or flash drive For this example we took a picture of the part and loaded the image by selecting USB gt Local HDD Images that reside on the machines local hard drive are selected from here Select image from Camera or USB Flash Drive Touch on USB C 68 69 17 00001 C Page 79 DN A Division of Phillips Corporation Create Better Ideas e 4 Insertion Points circled in GREEN Touch on to locate e Use GREEN ARROWS to center points over location 1 Select Points Identify Group 1 Insertion Points after touching and locating a point on the screen you have an opportunity to move the point directly over the insertion hole Touch on or touch and hold on the appropriate arrow to center insertion point over the desired insertion hole you want to move a point for example insertion point 2 of 4 you must delete the last 2 points 3 amp 4 using the button before you can reposition point 2 9 72 17 00001 Page 80 Nyy Haeger incorrPoratep A Division of Phillips Corporation Create Better Ideas amount This sc
129. tter Ideas Parts List Hydraulic Cooler Assembly ITEM NO 1 17 00001 C PART NUMBER 15 00783 15 01601 15 01393 11 00319 15 01132 15 01147 DESCRIPTION BRKT RESERVOIR COOLER MOUNT M6 WASHER ZINC PLATED LOCK WASHER M6 DIN127 ZINC SHCS M6 x 1 0 x 20MM STAINLESS COOLER 824 H S ECO 4 90 12 12 MALE BOSS TO MALE JIC 90 QTY Page 166 DN Haeger Create Better Ideas Decommissioning Your Machine The decommissioning of a Haeger machine is a rare occurrence as older models themselves being relocated or sold to other facilities around the world In the event a machine component requires replacement we recommend recycling the old Most countries have recycling programs for such components like computers petroleum based fluids metals and so on Contact your local governing agency or recycling center for details on proper containment and or disposal of the machine or used components Contact Haeger customer service department when you machine is no longer in use 17 00001 C Page 167
130. ystem section before attempting to operate this machine NEVER wear anything metallic that may come into contact with the Upper Tool Lower Tool or work piece watches rings bracelets etc Never leave your foot on or above the Down foot switch after you have completed a cycle of the machine Remove it fromthe Down foot switch Keep your feet away from the Down foot switch until your hands are clear of the tooling area and you intend to lower raise the Upper Tool Holder or insert hardware NEVER Operate this Machine without wearing the proper eye protection IS T 105 Turn the machine by turning the main disconnect switch to the ON position Conductive Mode e Turn key to the Right e 47 Key is removable in this position and should not stay with the machine key should be kept by a trained setup person or shop owner 106 107 Push Machine ON Switch 17 00001 C Page 93 DN Haeger Create Better Ideas The InsertionLogic banner screen will appear on the computer signifying that the computer is starting up Once the system environment is fully started the Log In screen will be displayed Access Level Reminder Advanced gt Run Run Programs Yes Yes Programs Filter Yes Yes Select Programs Yes Yes Create New Program Yes Yes Edit Loaded Program Yes Yes Preview Program Delete Prog Level Reminder

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