PennEngineering Haeger 824 WindowTouch-4e User manual

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824 WindowTouch4e
Operation Manual

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© 2012 HAEGER, INC. All 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 - INTRODUCTION........................................................................................................ 7
Congratulations!.............................................................................................................................7
Haeger Locations Worldwide .........................................................................................................7
Statement of Foreseen Use............................................................................................................9
Safety Information (also see section 3)..........................................................................................9
Customer Service (also see section 6) ............................................................................................9
Responsibilities of the Operator.....................................................................................................9
Responsibilities of the Service Technician................................................................................... 10
Quality of Parts & Fasteners........................................................................................................ 10
Basic data sheet........................................................................................................................... 11
Illistration of safety notes............................................................................................................ 12
Details of location in the documentation.................................................................................... 13
Safety precautions and warnings ................................................................................................ 14
SECTION 2 - INSTALLATION........................................................................................................ 15
Handling....................................................................................................................................... 15
Recommended Safe Work Zone.................................................................................................. 16
Skid removal ............................................................................................................................... 17
Machine setup............................................................................................................................ 18
Main power set-up ...................................................................................................................... 20
Machine operator basic controls................................................................................................. 21
Testing of the electrical set-up.................................................................................................... 23
The Upper Tool Holder ................................................................................................................ 25
The Turret Insertion System (T.I.S.)............................................................................................. 26
Tooling storage............................................................................................................................ 27
Quick mount mutli-shuttle .......................................................................................................... 28
Quick mount TIS-3 ....................................................................................................................... 29
Quick Mount Auto Tooling .......................................................................................................... 30
Modular Auto Feed System (MAS 350) ....................................................................................... 31
Conductive mode set-up procedure ................................................................................... 32
Getting started –Before you turn on the machine ............................................................... 32
Setting the machine............................................................................................................... 32
Checking the up travel & insertion ........................................................................................ 32
Non-conductive mode set-up procedure ............................................................................ 34

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Getting started –Before you turn on the machine ............................................................... 34
Setting the machine............................................................................................................... 34
Checking the up travel & insertion ........................................................................................ 34
SECTION 3 –HAEGER SAFETY SYSTEM........................................................................................ 36
Safety system description............................................................................................................ 37
Conductive Mode ........................................................................................................................ 37
Non-conductive mode................................................................................................................. 37
How the safety system works...................................................................................................... 37
Lockout-Tagout............................................................................................................................ 39
Fire Safety Equipment ................................................................................................................. 42
Safety Awareness & Residual Risks .................................................................................... 43
Introduction ........................................................................................................................... 43
1. Situations and Actions to Avoid......................................................................................... 43
2. Residual Safety Risks.......................................................................................................... 43
Operator Safety Awareness & Residual Risks........................................................................ 44
Maintenance Safety Awareness & Residual Risks ................................................................. 46
Safety System Tests........................................................................................................... 47
Step 1: Safety switch test procedure..................................................................................... 47
Step 2: conductive mode test ................................................................................................ 49
Step 3: Non-conductive mode test ........................................................................................ 51
SECTION 4 –TOUCH SCREEN OPERATION (Step by Step Demo)................................................... 53
Window Touch-4e - Introduction ................................................................................................ 53
Touch Screen Hierarchy Overview .............................................................................................. 54
Quick Run Step by Step Demo ........................................................................... 56
User Login.................................................................................................................................... 57
Password...................................................................................................................................... 57
Input 1: Station............................................................................................................................ 58
Input 2: Material.......................................................................................................................... 58
Input 3: Fastener ......................................................................................................................... 58
Input 4: Unit & Size...................................................................................................................... 59
Input 5: Insertion Values ............................................................................................................. 59
Force (LBS) ............................................................................................................................. 59
Dwell (Sec).............................................................................................................................. 60
Up Travel (%).......................................................................................................................... 60
Input 6: MAS Values .................................................................................................................... 60
Eject Time (Sec)...................................................................................................................... 60
Vibration (%) .......................................................................................................................... 61
Vibration Time (Sec)............................................................................................................... 61
Input 7: Quality Control............................................................................................................... 61
Tooling Protection System (TPS)............................................................................................ 61
Fastener Length ..................................................................................................................... 62
Fastener Detection................................................................................................................. 62
Input: Status ................................................................................................................................ 62
Clamp ..................................................................................................................................... 62
Vacuum .................................................................................................................................. 63

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Tooling ................................................................................................................................... 63
Modular Auto Feed System (MAS)......................................................................................... 63
Eject Fastener......................................................................................................................... 64
Setup Stroke........................................................................................................................... 64
Programs Setup Step by Step Demo .................................................................... 66
User Login.................................................................................................................................... 68
Password...................................................................................................................................... 68
Programs...................................................................................................................................... 69
Create New Program ................................................................................................................... 69
Program Name............................................................................................................................. 69
New Customer............................................................................................................................. 70
Program Notes............................................................................................................................. 70
Fastener Differentiation .............................................................................................................. 70
Program Wizard (Automatic or Manual, Station 1 of 4).............................................................. 71
1. Preset: ................................................................................................................................ 71
Library............................................................................................................................. 71
Part Material................................................................................................................... 71
2. Fastener: ............................................................................................................................ 71
Manufacturer.................................................................................................................. 71
Type ................................................................................................................................ 72
3. Size ..................................................................................................................................... 72
Unit of Measure.............................................................................................................. 72
Fastener Length.............................................................................................................. 72
Part Identification........................................................................................................... 72
4. Select Tooling Type ............................................................................................................ 73
Program Wizard (Manual, Station 2 of 4).................................................................................... 73
Program Wizard (Manual, Station 3 of 4).................................................................................... 75
Program Wizard (Manual, Station 4 of 4).................................................................................... 76
Add Insertion Group (Station 1) .................................................................................................. 78
Amount .................................................................................................................................. 78
Part Image.............................................................................................................................. 79
Location: USB HDD................................................................................................................. 79
Select Insertion Points ........................................................................................................... 80
Add Insertion Group (Station 2) .................................................................................................. 81
Add Insertion Group (Station 3) .................................................................................................. 83
Add Insertion Group (Station 4) .................................................................................................. 85
Insertion Group Program Correction Example (Station 3) .......................................................... 88
Save Program............................................................................................................................... 91
Run Program Step by Step Demo........................................................................... 92
User Login.................................................................................................................................... 94
Password...................................................................................................................................... 95
Production Run Overview............................................................................................................ 96
Batch Size..................................................................................................................................... 96
Parts Completed.......................................................................................................................... 96
MAS Vibration (%) ....................................................................................................................... 96
MAS.............................................................................................................................................. 96

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Preview........................................................................................................................................ 96
Station 1 Insertion –Start Production......................................................................................... 97
Setup Stroke........................................................................................................................... 97
Adjusting Insertion Values ..................................................................................................... 98
Another Setup Stroke Is Required After Adjustments........................................................... 99
Station 2 Insertion ..................................................................................................................... 102
Station 3 Insertion ..................................................................................................................... 105
Station 4 Insertion ..................................................................................................................... 108
SECTION 5 - OPTIONS ...............................................................................................................112
SECTION 6 –MACHINE MAINTENANCE .....................................................................................113
Maintenance Schedule.............................................................................................................. 113
Trouble Shooting ....................................................................................................................... 115
Weekly Care & Maintenance.............................................................................................124
(MAS 350): Care & Maintenance ......................................................................................... 124
Flight Tube: Care & Maintenance ........................................................................................ 125
Upper Tool Changer: Care & Maintenance.......................................................................... 126
Upper Tool Holder: Care & Maintenance ............................................................................ 127
Diagnostics: From Main Screen ...................................................................128
PLC1 I/O Screen ......................................................................................................................... 129
PLC I/O....................................................................................................................................... 130
Schematics & Diagrams ............................................................................................................. 131
Customer Service....................................................................................................................... 132
SERVICE TEAM ........................................................................................................................... 133
Warranty.................................................................................................................................... 134
SECTION 7 –PARTS LIST............................................................................................................135
Description................................................................................................................................. 135
Parts List - Main Assembly......................................................................................................... 136
Parts List - MAS 350 Bowl Assembly.......................................................................................... 138
Parts List –Upper Tool Holder Assembly .................................................................................. 140
Parts List - Quick Mount Assembly............................................................................................ 141
Parts List - Muti-Shuttle 2 Assembly.......................................................................................... 143
Parts List - HMI Arm Assembly .................................................................................................. 145
Parts List - TIS Assembly ............................................................................................................ 147
Parts List - Vacuum Generator Assembly .................................................................................. 150
Parts List –Service Tray Assembly............................................................................................. 151
Parts List –Positive Stop System Assembly............................................................................... 152
Parts List –Hydraulic Cylinder Main Assembly.......................................................................... 153
Parts List –Electrical Cabinet High/Low Voltage Assembly....................................................... 155
Parts List –Printed Circuit Board Assembly............................................................................... 157
Parts List –Hydraulic Reservoir Assembly................................................................................. 158
Parts List –Hydraulic Manifold Assembly ................................................................................. 161

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Parts List –Hydraulic Suction Filter Assembly........................................................................... 163
Parts List –Return Filter Assembly............................................................................................ 164
Parts List –Motor Pump Assembly............................................................................................ 165
Parts List –Hydraulic Cooler Assembly...................................................................................... 166
Decommissioning Your Machine............................................................................................... 167

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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’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
811 Wakefield Drive
Oakdale, California 95361
USA
[phone]
[phone]
Fax: [phone]
Haeger Europe
Textielstraat 18
7575 CA Oldenzaal
The Netherlands
Phone: [phone]
Fax: [phone]

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EC DECLARATION OF CONFORMITY
Manufacturer & 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 WT -4 H or L
Serial Number: 8WT4xxxx
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 +A1:2008
ISO 60204-1: 2006 +A1:2009
ISO 12100-1: 2010
EN 982: 1996 +A1:2008
ISO 14121-1: 2007
ISO 12100-2: 2010
EN 953: 1997 +A1:2009
ISO 13849-1: 2008

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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 All 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.
It is recommended that in addition the safety details in this Haeger insertion machine
manual, all customers, create, implement and maintain their own individual safety 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 candidate. 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

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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 with proper tools
for the installation and maintenance of the machine.
Quality of Parts & 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 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.