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PennEngineering Haeger 824 WindowTouch5He Operation Manual

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824 WindowTouch5H
Operation Manual
17-00076 Rev.D.8.2024

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Summary of Contents for PennEngineering Haeger 824 WindowTouch5He

  • Page 1 824 WindowTouch5H Operation Manual 17-00076 Rev.D.8.2024...
  • Page 2 © 2022 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 here of and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 - INTRODUCTION ..........................1 Congratulations!................................ 1 Haeger Locations Worldwide ............................ 1 Statement of Foreseen Use ............................2 Safety Information ..............................2 Customer Service ............................... 2 Responsibilities of the Operator ..........................2 Responsibilities of the Service Technician ......................... 2 Basic Maintenance ..............................
  • Page 4 Safety System Description ............................29 Tooling Protection System ............................31 Lockout-Tagout ............................... 32 Fire Safety Equipment ............................. 33 Safety Awareness & Residual Risks ......................... 34 Operator Safety Awareness & Residual Risks ..................... 35 Maintenance Safety Awareness & Residual Risks ....................37 Safety System Tests ..............................
  • Page 5 Sheet Metal (Pt.1) ..............................108 Sheet Metal (Pt.2) ..............................109 Electrical Cabinet ..............................111 MAS 350 Bowl Assembly ............................114 Dual Safety Sensor (15-42360) & Upper Tool Holder (15-40036) ................116 Quick Mount Assembly (15-40026) ........................118 Multi-Shuttle Assembly (15-40027) ........................120 TIS-3 Assembly (15-41593) ............................

  • Page 6: Section 1 - Introduction

    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 thirty 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.

  • Page 7: Statement Of Foreseen Use

    Statement of Foreseen Use The WindowTouch-5He 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 or 60Hz with no additional power requirements.

  • Page 8: Basic Maintenance

    Basic Maintenance The customer is responsible for basic maintenance of the machine, including but not limited to:  Cleaning the machine regularly to prevent the buildup of dirt and debris.  • Inspecting the machine regularly for signs of wear and tear.  •...

  • Page 9: Basic Data Sheet

    Basic Data Sheet YOUR Machine Model 824 Window Touch -5He Serial Number: Year Manufactured: Voltage: Amperes: Hertz (Machine): Hertz (MAS): Phase: 824 WindowTouch 5e Machine Matrix Voltage 208/240 380/480 Amperage Hertz 50 or 60 50 or 60 50 or 60 Phase Noise Measurement Summary LEX 8-hour...

  • Page 10: Illustrations Of Safety Notes

    Illustrations 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.

  • Page 11: Details Of Location In The Documentation

    Details of Location in the Documentation All information in these instructions concerning direction and location refer to the workplace of the operator. Rear Side of Machine Right Side Left Side Front Side 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 and facing the work area Eye protection must be worn when operating this machine...

  • Page 12: Safety Precautions And Warnings

    Safety Precautions and Warnings Operate this Haeger Hardware Insertion Machine without proper Never instructions. Read and thoroughly understand this manual before attempting to operate this machine. Tamper with any part of this machine’s electrical system unless you Never are a trained electrician and thoroughly understand this machine’s electrical schematic.

  • Page 13: Section 2 - Installation

    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. ...

  • Page 14: Recommended Safe Work Zone

    Recommended Safe Work Zone Prior to delivery, it is recommended that an area is laid out which allows operator and maintenance personnel ample space to work or service the machine. The distances shown below are general guidelines. It is the customer’s responsibility to adjust this “Safe Work Zone”...

  • Page 15: Skid Removal

    Skid Removal  The feet are already installed on the machine.  You will need to lift the machine to remove the skids.  You will need three different wrenches. Skid Bolt: 9/16 in./13mm socket 9/16”/13mm socket wrench Feet: 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...

  • Page 16: Machine Setup

    Machine Setup 1. Place the machine carefully in your shop. The surface should be flat, level, and hard enough to support the machine's weight, which is detailed in the 'Basic Data' section of this manual. If you're unsure whether the surface can hold the machine's weight, consult a structural engineer. As of the time this manual was published, there are no known requirements to secure or anchor the machine to the surface.
  • Page 17 Machine Setup (continued) If the machine is equipped with a Modular Auto Feed System (MAS): must be connected to the machine. Connect airline to the shut-off valve attached to the air regulator located at the back of the machine. Use only an airline that supplies clean, dry air. Air Flow Air Pressure 3 ft 3 /min - 85 l/min...

  • Page 18: Main Power Setup

    Main Power Setup 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.

  • Page 19: Machine Operator Basic Controls

    Machine Operator Basic Controls All the operator controls except the foot pedal are through the touch screen interface to the right of the machine. There are E-Stop buttons/Stop buttons are on both right and left sides of the machine. Touch Screen Control Panel This is the primary interface to the operation control system.

  • Page 20: Footswitch

    Footswitch Footswitch is shielded and connected to the Haeger Machine by a heavy-duty cable. It contains both the Down and Up Footswitches When the Down Footswitch is depressed, the cylinder ram moves down. Releasing the Down Footswitch will stop the ram. Depressing the Down Footswitch again will recommence downward ram movement. In Conductive Mode, the machine will complete one normal cycle of the insertion process when the Down Footswitch is depressed and held down.

  • Page 21: Testing Motor Phase (Direction Check)

    Testing Motor Phase (Direction Check) The Machine Setup must be completed before initiating this test. 1. Open Side Panels from machine base so that the Motor is in view. Turn the machine’s Main Disconnect Switch to the ON position. 2. Twist the Red Mushroom Button (E-stop button) to be sure they are unlatched. 3.
  • Page 22 Testing Motor Phase (continued)  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. 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.

  • Page 23: The Upper Tool Holder

    The Upper Tool Holder The Upper Tool Holder is secured to the machine’s cylinder rod by the black serrated knob in the front. This Upper Tool Holder can usually be left on the machine. If it requires removal, do so with care. Continuity springs and guide pins inside the Upper Tool Holder may be easily knocked out during removal.

  • Page 24: Quick Mount Multi-Shuttle Platform

    Quick Mount Multi-Shuttle Platform The Multi-Shuttle Platform is a 1-piece, single station module for holding shuttle tooling. Integrated electrical/air supply connections on the module allows quick mounting and removal from the machine. Step 2: Slide the multi- Step 1: Mount shuttle shuttle into the positive tooling to the bottom of locking holder.

  • Page 25: The Turret Insertion System (Tis)

    The Turret Insertion System (TIS) Do not operate the machine without both the Upper and Lower Tools properly locked in place. The TIS Lower Tool Holder is secured to the lower arm of the machine’s frame by a M16 X 50 SHCS (Socket Head Cap Screw) and aligned by pins on the bottom of the assembly.

  • Page 26: Universal Lower Tool Holder H-166-8

    Universal Lower Tool Holder H-166-8 The Universal Lower Tool Holder, H-166-8, is a single station lower tool holder that can be used for situations where the TIS’s turret arms are in the way of certain workpiece shapes. It is also used for Bottom Auto-Feed Tooling (ABFT).

  • Page 27: Quick Mount Auto Tooling

    Quick Mount Auto Tooling Installation and Changeover in Two Easy Steps Step 1: Place tooling onto the MAS adapter, align the module using the locking and alignment pins. Step 2: Ensure the module is seated flush, and then push the lever towards the MAS bowl to lock.

  • Page 28: Modular Auto Feed System (Mas 350)

    Modular Auto Feed System (MAS 350) Modular Auto Feed System (MAS): This system allows the operator to run the MAS 350 bowl either at a continuous vibration or at intermittent vibration. Continuous vibration is commonly used when emptying the bowl out of hardware for a tool change or for small quantity hardware runs. Intermittent vibration is commonly used for normal high volume insertion applications.

  • Page 29: Quick Startup Procedure

    Quick Startup Procedure This procedure assumes that you are thoroughly familiar with this machine’s basic 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.

  • Page 30: Positive Stop System Assembly

    Positive Stop System Assembly he Positive Stop System provides an easily adjustable method to precisely maintain a stopping point of the machine cylinder. This system is well suited for improving uniformity on delicate work pieces made of softer materials such as aluminum, fiberglass, or composite. It can also be used for inserting small hardware.

  • Page 31: Positive Stop System Setup Procedure

    Positive Stop System Setup Procedure This Setup Procedure can be used for production runs in both Conductive and Non-Conductive Modes. This setup procedure assumes that you are thoroughly familiar with this machine’s operating controls, safety systems, and conductive/non-conductive Modes. If you are not familiar with the above stated controls and systems, STOP! Go to those sections and become familiar with all of them before continuing.
  • Page 32 11. Turn the Tube Assembly clockwise (right) approximately two revolutions. 12. Check your settings. Prepare hardware and workpiece for another insertion. 13. Bring the Punch down until it contacts the workpiece and stops. 14. Depress the Down Footswitch a second time, the machine should install the hardware and stop. 15.

  • Page 33: Section 3 - Haeger Safety System

    SECTION 3 – HAEGER SAFETY SYSTEM Safety Precautions and Warnings Operate this Haeger Hardware Insertion Machine without proper Never instructions. Read and thoroughly understand this manual before attempting to operate this machine. Tamper with any part of this machine’s electrical system unless you Never are a trained electrician and thoroughly understand this machine’s electrical schematic.

  • Page 34: Safety System Description

    Safety System Description The Haeger Hardware Insertion Machine is equipped with a unique, reliable 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.
  • Page 35 In non-conductive mode:  Foot pedal must be released and pressed a second time.  Within safe position set by the TPS. Before each cycle, the state of the two sensors in the ram adapter are monitored by the dedicated Safety Controller.

  • Page 36: Tooling Protection System

    Tooling Protection System The Tooling Protection System (TPS) is intended for protecting the tooling and/or workpiece from damage in the event of wrong length fasteners or unintended obstructions that come in between the workspace. This system works in conjunction with the Safety System. The TPS is programmed during “Setup Stroke” at the beginning of each project.

  • Page 37: Lockout-Tagout

    Lockout-Tagout Lockout-Tagout is a safety procedure used to ensure that malfunctioning machines are properly shut off during maintenance or servicing. Before any repair work begins, the machine is isolated from hazardous power sources and rendered inoperative. The procedure involves locking the device or power source and attaching a tag to indicate that it should not be turned on.

  • Page 38: Fire Safety Equipment

    Fire Safety Equipment Haeger systems do not produce thermal, biological, fire or radiation hazards. However, having a Multi- Class rated fire extinguisher within reasonable distance from the machine and operator(s) is sound safety practice and is recommended. Your fire extinguisher(s) should be able to extinguish fires involving ordinary combustible materials, flammable/combustible liquids and energized electrical equipment.

  • Page 39: Safety Awareness & Residual Risks

    Safety Awareness & 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 situations and behaviors to avoid in order to prevent injury. The 2 principle describes residual risks that are inherent of the machine and cannot be removed.

  • Page 40: Operator Safety Awareness & Residual Risks

    Operator Safety Awareness & Residual Risks Risk of crushing: A high risk crushing hazard is created between the Punch and Anvil. Safety of the operator in non- conductive operation must remain accessible only to trained and authorized personnel that are experienced in appropriate machinery operating conduct.
  • Page 41 Risk of pinching: A medium risk pinching hazard is created by the Multi-Shuttle moving backward and forward Risk of pinching: A medium risk pinching hazard is created by the TIS when rotating for the next station. 17-00076 Rev.D.8.2024...

  • Page 42: Maintenance Safety Awareness & Residual Risks

    Maintenance Safety Awareness & Residual Risks 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 components. High Voltage hazard is ALWAYS present in this location, until INCOMING (MAIN) power is shut OFF.

  • Page 43: Safety System Tests

    Safety System Tests There are three (3) Safety Tests in total. Do not skip or ignore any of them! 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. Step 1: Safety Switch Test Procedure machine will always prompt this first test upon turning on the Main Disconnect Switch (main power).

  • Page 44: Step 2: Conductive Mode/Tps Test

    Step 2: Conductive Mode/TPS Test 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 this manual. NEVER Operate this Machine without the proper tooling installed. following instructions assumes the first Safety Sensor test has been performed and passed.
  • Page 45 Step 2: Conductive Mode Test (Cont.) 7. Place a non-conductive material (paper or cardboard recommended, harder materials may damage tooling if vacuum tip has a protruding pin) above the anvil, making sure the object completely covers the top surface of the Anvil. Keep your hands away from the tooling area. Depress and hold the Down Footswitch.

  • Page 46: Step 3: Safety Gap Test

    Step 3: Safety Gap Test 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 this manual. NEVER Operate this Machine without the proper tooling installed. The following instructions assumes the first Safety Sensor test has been performed and passed.
  • Page 47 Step 3: Safety Gap Test (Cont.) • This measurement must be at least .060” in. /1.52 mm or more for the safety systems to function properly. • If this measurement is less than .060” in. /1.52 mm, the gap is insufficient and must be addressed.

  • Page 48: Section 4 - Touch Screen Operation (Step By Step Demo)

    SECTION 4 – TOUCH SCREEN OPERATION (Step by Step Demo) Window Touch-5He - Introduction This section provides you, the operator, with all the information that you need to operate the Haeger 824 WindowTouch-5He safely and productively. Make sure that you read and understand all the descriptions, instructions and notes contained in this section.

  • Page 49: Touch Screen Hierarchy Overview

    Touch Screen Hierarchy Overview 17-00076 Rev.D.8.2024...

  • Page 50: User Level Security Access

    User Level Security Access User level security access, each login account is assigned a security level by the administrator. When the machine is first powered On or when operator change occurs, the user security level must be selected to access the Run or Start Production screen. Access & permissions are as follows: Haeger Administrator Adv.

  • Page 51: Quick Run Step By Step Demo

    Quick Run Step by Step Demo The 824 WindowTouch-5He 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. The touch screen is the main method of entering information into the software and controlling the computer.
  • Page 52 Touch on Quick Run Touch on Turn on Machine to start the motor. Station: Station is a high volume, Automatic insertion • station working in conjunction Select Station with the Modular Automated Feed • Touch on Station 1 System (MAS). Stations Manual insertion stations.
  • Page 53 Tooling: This feature allows the operator to select the type of tooling to run in the selected station. Tooling Options are: Manual, Shuttle, Bottom Feed, and J-frame • Tooling • Set to Shuttle Touch on Select Fasteners to open the fastener selection menu.
  • Page 54 Fastener: Blind Standoff (BSO,  BSOS, TSO, TSOS) Nut (CLS, CLSS, S, SS)  Flush Nut (F)  Standoff (SO, SOS)  Stud (FH, FHS, TFH. TFHS)  Heavy Duty Stud (HFH,  HFHS) • Select Fastener. • Touch on FH (Stud) Unit &...

  • Page 55: Tooling Control

    Touch OK to confirm selection Force (lbs): Is the amount of force that will be applied during the hardware insertion cycle. The force can range from 800 pounds (3.6KN) to 16,000 pounds (71.2 KN). The 3300 lbs value displayed is derived from a manufacturers table of values, however it can be adjusted by touching the...

  • Page 56: Mas Values

    Up Travel (%): The Up Travel value controls the Up Position of the ram. This is the upward position the ram returns to after applying insertion force. The Up value is measured as a percentage of the total cylinder stroke. It will vary depending on the lengths of the Upper and Lower Tools.

  • Page 57: Quality Control

    Vibration Time (Sec): Vibration Time controls the duration that the MAS 350 bowl will vibrate after a fastener has been ejected. Adjust the vibration time as needed to keep a full track of • Vibration Time (Sec) hardware. • Set to 1.0 The 1 (sec) value shown is a starting point only.

  • Page 58: Status

    Turret Insertion System (TIS): This feature allows the operator to unlock the TIS allowing it to rotate for the installation of the lower tools. • TIS (Turret Insertion System) • Set to Locked Status Vacuum: This feature allows the operator to switch the vacuum system ON or OFF on the vacuum punch.

  • Page 59: Setup Stroke

    • • Change to intermittent vibration for auto-feeding • Eject Fastener: This feature allows the Eject Fastener operator to eject a fastener from the MAS • Tap to eject fastener for bowl to the work area. insertion Setup Stroke : This feature sets up and records certain values for each station and project run.
  • Page 60 Setup Stroke Step 1 - Station Begins moving ram down slowly as system detects and records fastener pickup point (Fastener Detection) and Fastener Length, and insertion point. Upper tool in motion • Setup Stroke step 1 Letting go of the Down Footswitch will stop ram movement.
  • Page 61 Touch on Next Touch on Yes if the Setup Stroke is now complete for insertion force is correct. Station , and the system is ready Touch No to make for continuous insertions with current adjustments. tooling. Repeat for Stations Stations 2-3 are manual tooling stations.

  • Page 62: Programs Setup - Step By Step Demo

    Programs Setup - Step by Step Demo 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).
  • Page 63 The 824 WindowTouch-5He 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. The touch screen is the main method of entering information into the software and controlling the computer.

  • Page 64: Create New Program

    Touch on Programs Create New: Begins a new program. Programs are stored on the machine’s hard drive. • Create a new program • Touch on Create Program Create New Program Program Name: Name to identify the program for later. For this example, use “Program Demo Plate 1 “...

  • Page 65: Fastener Library

    New Customer: Adds a new Customer to the internal database. If a customer had been previously entered, choose “Existing” to see the list for selection. Touch on New • Touch to bring up keyboard • Enter “Haeger, Inc.” • Touch Ok Program Notes: Space for any notes as necessary.
  • Page 66 Part Material: Material of the work piece/panel (Not the fastener). • Select Part Material • Touch on the Steel Fastener Type: Blind Standoff (ex. BSO)  Standoff (ex. SO)  Stud/Pin (ex. FH, HFH)  Nut (ex. CLS, S)  •...
  • Page 67 • Select Length Length: Fastener length • Touch on 10 Select Tooling Type: Shuttle tooling (automatic tooling) is typically setup on station 1 (automatic • station). Select Tooling Type • Touch on Shuttle When ready, use arrows to move to next setup. Tooling: Select tooling set for the job.
  • Page 68 Quality Control: Sensitivity Values: TPS Sensitivity Values: Minimum of 0.1, maximum of 1. Set Fastener Fastener Length Sensitivity: Minimum of 0.1, maximum of 5. Detection Fastener Detection Sensitivity: Minimum of 0, maximum of 1.813. Set Sensitivity Values Touch on Station 2 Repeat Wizard to program Station * This time select a Nut: S-632-2.
  • Page 69 • Select Unit • Touch on Unified • Select Fastener Type • Touch on S • Select Size • Touch on 632 • Select Length • Touch on 2 Select Tooling Type: Stations 2 through 4 are manually • Select Tooling Type operated stations.
  • Page 70 When ready, use arrows to move to next setup. Set Insertion Values TPS Sensitivity Values: Minimum of 0, maximum of 1. Fastener Length Sensitivity and Fastener Detection Sensitivity not applicable for manual tooling. Set Sensitivity Values Touch on Station 3 Repeat Wizard to program Station * This time select a Stud FH-632-6.
  • Page 71 Step through Wizard by touching on the selections shown below Select Manual Tooling When ready, use arrows to move to next setup. Set Insertion Values Set Sensitivity Values 17-00076 Rev.D.8.2024...
  • Page 72 Touch on Station 4 Speed up the programming steps by using Search Fastener in lieu of the wizard to program Station Touch on the Search * This time select a Nut CLS-M10-1. Fastener tab Touch on Global Touch on Fastener Name To go directly to the desired fastener, •...
  • Page 73 Select CLS-M10-1 Touch on Steel Select Manual 17-00076 Rev.D.8.2024...

  • Page 74: Insertion Groups

    Move to next step Set Insertion Values Move to next step Set Sensitivity Values Adding Insertion Groups For this example, create 4 insertion Touch on Add to create groups. an Insertion Group. Insertion Groups 17-00076 Rev.D.8.2024...
  • Page 75 Station Number: Touch on the Station Tapping the Station Column in each column to change the row (group) multiple times will toggle through the station numbers. station # For this example, set the stations in order from 1 to 4. Amount: This column sets the number of fasteners to be inserted for each...
  • Page 76 Picture: This icon associates a part image with the insertion group. • Select a part picture for hardware insertion • Touch on Picture Icon for insertion group 1 Images can be selected from different locations. • USB: Typically used to pull Select image from Local ...
  • Page 77 • Touch the location for each insertion on the part. • Select Points: Add Insertion Points to the GREEN ARROWS to center points over location image by tapping the desired location on the image. Use the four direction arrows on screen to fine-tune and center the point.
  • Page 78 • Touch the location for each insertion on the part. Select Points: Add Insertion Points to the • GREEN ARROWS to center points over location image by tapping the desired location on the image. Use the four direction arrows on screen to fine-tune and center the point.
  • Page 79 • Touch the location for each insertion on the part. • GREEN ARROWS to center points over location Select Points: Add Insertion Points to the image by tapping the desired location on the image. Use the four direction arrows on screen to fine-tune and center the point.

  • Page 80: Editing Insertion Groups

    • Touch the location for each insertion on the part. Select Points: Add Insertion Points to the • GREEN ARROWS to center points over location image by tapping the desired location on the image. Use the four direction arrows on screen to fine-tune and center the point.
  • Page 81 Touch on Yes Add point(s) Touch on OK Touch on Save to save the Insertion Program 17-00076 Rev.D.8.2024...

  • Page 82: Run Program - Step By Step Demo

    Run Program - Step by Step Demo This section provides you, the operator, with the information that you need to run a Program and operate the Haeger 824 WindowTouch-5He safely and productively. Machine Controls Touch Screen Emergency Stop Foot Switches ...
  • Page 83 Access Level Reminder: Advanced Haeger Administrator Administrator Operator Level Machine User Technician Programs Filter Select Programs Create New Program Edit Loaded Program Preview Program Start/Load Program Edit Selected Program Delete Program Administrator/Operator  Access Level Reminder: Login, Load Program, Close Program, Machine User does not have access to load a Logout Program.
  • Page 84 Enter Password Touch on Programs Select desired program Touch on Start/Load 17-00076 Rev.D.8.2024...
  • Page 85 Production Run Overview Program Action • Batch Size: Is how many parts you must complete. Touch on the value itself, to touch type a new value. • MAS Vibration (%): This feature allows the operator to increase or decrease the vibration intensity of the MAS 350 bowl.
  • Page 86 Setup Stroke: This feature sets up and records the fastener pickup point, fastener length, and insertion point. This only needs to be setup the first time for each station when running a program. Depress the Down Upper tool in motion Footswitch.
  • Page 87 Yes: Insertion was completed successfully and ready to move on to next insertion point • Was hardware inserted No: Opens the Adjust Fastener correctly? Window. Change Insertion and/or MAS values as needed. • Touch on Yes or No ADJUSTING INSERTION VALUES Increase or decrease the value by touching the symbols on...
  • Page 88 TIS is now unlocked, allowing it to be turned to the next Station. When the correct position is reached, the TIS will automatically lock. Turn TIS to Station 2 Manually place fastener into manual tooling • Station tooling and fastener is in place &...
  • Page 89 Depress Footswitch again to apply insertion force • Check Part • Touch on Next Confirm force and insert rest of fasteners according to program if any. 17-00076 Rev.D.8.2024...
  • Page 90 TIS is now unlocked, allowing it to be turned to the next Station. When the correct position is reached, the TIS will automatically lock. Turn TIS to Station 3 • Station tooling and fastener is in place & ready Manually place fastener •...
  • Page 91 Confirm setup and insert rest of fasteners according to program if any. TIS is now unlocked, allowing it to be turned to the next Station. When the correct position is reached, the TIS will automatically lock. Turn TIS to Station 4 Manually place fastener into tooling •...
  • Page 92 Setup Stroke: This feature sets up and records the fastener pickup point, fastener length, and insertion point. This only needs to be setup the first time for each station when running a program. Upper tool in motion Follow Setup Stroke steps Confirm setup and finish inserting rest of fasteners if any...
  • Page 93 Program Ends and returns to Main Screen 17-00076 Rev.D.8.2024...

  • Page 94: Section 5 - Options

    SECTION 5 - OPTIONS Component Part # Description Picture Laser – Part 15-01801 Provides a highly visible, red- Locating Light laser indicator to aid in locating the lower tool under larger parts. Increases productivity and decreases operator fatigue. 17-00076 Rev.D.8.2024...

  • Page 95: Section 6 - Machine Maintenance

    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).
  • Page 96 Maintenance Schedule (Cont.) *Hydraulic Fluid The machine uses Exxon Humble Hydraulic H AW-32. Equivalent ISO 32 Viscosity Grade Hydraulic oils may used. ** Lithium Grease Each Haeger machine is shipped with a tube of Lubriplate 630-AA. This is the recommended grease to use for lubricating parts around the machine.

  • Page 97: Troubleshooting

    Troubleshooting Problem Source Solution Machine has no Disconnect Turn disconnect switch to the On position. power. switch is off. 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 any damage and alignment to the attachment bar.
  • Page 98 Problem Source Solution Fastener will not MAS bowl is Check to ensure there is enough fasteners in the MAS Bowl. feed. empty. Check the MAS module(s) to ensure that there are no fasteners MAS module(s) or debris jammed in the fastener tracks. jammed.
  • Page 99 Problem Source Solution No pressure is Check the condition of the proportional amplifier. built. Ram comes Ensure that you are in the right mode for the material you are Running non- down, taps conductive running. workpiece, and material while in then returns up.

  • Page 100: Weekly Care & Maintenance

    Weekly Care & Maintenance This maintenance schedule is applicable for standard machine shop operating conditions. When operating in severe conditions such as heavy dust or dirt or running 24 hours, increase the schedule to reflect such conditions. MAS 350 Bowl: Care & Maintenance •...

  • Page 101: Flight Tube: Care & Maintenance

    Flight Tube: Care & Maintenance • Dirt, grease, debris builds up over time in the tubes. • It is recommended to blow out flight tube after each tool change. • 1 : Detach tube(s) from MAS 350 Module and upper tool changer.

  • Page 102: Multi-Shuttle: Care & Maintenance

    Multi-Shuttle: Care & Maintenance It is recommended to dust out the multi shuttle weekly or more depending on usage. • Use dry compressed air to blow out debris Eye protection must • be worn DO NOT use rubbing alcohol, WD-40, diesel, gas, etc., to clean shuttle slides! If necessary, denatured alcohol can be applied to a clean cloth to remove dirt and grease.

  • Page 103: Upper Tool Holder: Care & Maintenance

    Upper Tool Holder: Care & Maintenance It is recommended to inspect the upper tool holder and its contacts DO NOT use rubbing alcohol, WD-40, diesel, weekly or more frequently gas, etc., to clean contacts or any part of the holder! based on usage.

  • Page 104: Tis-3: Care & Maintenance

    TIS-3: Care & Maintenance DO NOT use rubbing alcohol, WD-40, diesel, It is recommended to gas, etc., to clean contacts or any part of the TIS-3! inspect the TIS-3 and its contacts weekly or more • : If it is necessary to frequently based on usage.

  • Page 105: Diagnostics: From Main Screen

    Diagnostics: From Main Screen Touch on Admin Touch on Diagnostics 17-00076 Rev.D.8.2024...
  • Page 106 Digital Inputs (DIxx): These are inputs for the PLC from various points on the electrical board. These Inputs determine what Outputs will be turned on at certain times. 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 functions.

  • Page 107: Schematics & Diagrams

    Schematics & Diagrams Schematics and Diagrams are customized to accurately depict your machine and will not be bound in this operation manual. They will be delivered separately on large format paper in an effort make them legible and easy to read. Typical Drawing List: ...

  • Page 108: Customer Service

    Customer Service Haeger is proud of its 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. A service tech will contact you within 24 hours To save time, please be prepared to give your area Haeger Representative the following information: 1.

  • Page 109: Limited Warranty

    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.

  • Page 110: Section 7 - Parts List

    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 Numbers : Are depicted with in a circle with an arrow pointing to the specific part or assembly. Part Number: Identifies a specific item in Haeger’s inventory.

  • Page 111: Main Assembly

    Main Assembly 17-00076 Rev.D.8.2024...
  • Page 112 Main Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03969 LABEL, MACHINE LOGO, 6X6, 824WT5e 11-00515 MACHINE LABEL, "LIFT HERE" 11-00361 LABEL, HAEGER WARNING 16-00134 LABEL, ELECTRIC SHOCK WARNING 11-00233 LATCH KEY- 824 15-00220 DISCONNECT HANDLE 11-00232 DOOR LATCH 15-03955 HMI ARM 15-03538 LABEL, E-STOP LEGEND, YELLOW BLANK 15-03067...

  • Page 113: Sheet Metal (Pt.1)

    Sheet Metal (Pt.1) 17-00076 Rev.D.8.2024...

  • Page 114: Sheet Metal (Pt.2)

    Sheet Metal (Pt.2) 17-00076 Rev.D.8.2024...
  • Page 115 Sheet Metal ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03148 CYLINDER TOP COVER, (-5e) WT/OT 15-03574 COVER, POSITIVE STOP, WT/OT 15-03081 CYL. TOOL CABINET DOOR LINKAGE LATCH, WT/OT 15-02793 ANVIL STOR., TOOLING CABINET CYLINDER, WT (-5) 15-02795 DOOR, TOOLING CABINET CYLINDER, WT (-5) 15-02740 FRONT COVER, CYLINDER, WT (-5) 15-02794...

  • Page 116: Electrical Cabinet

    Electrical Cabinet 17-00076 Rev.D.8.2024...
  • Page 117 Electrical Cabinet ITEM NO. PART NUMBER DESCRIPTION QTY. 15-02734 CABINET, ELECTRICAL, WT (-5) 15-03961 ELECTRICAL PANEL A, LOW VOLTAGE 15-02745 ELECTRICAL PANEL B, HIGH VOLTAGE 15-03887 UNIVERSAL CONTROL BOARD, (-5) 15-03907-1 COMPUTER, BOX PC 15-03974 CONTROLLER MAS350 10-00019 PANDUIT WIRING DUCT 15-00220 DISCONNECT HANDLE (PISTOL GRIP) 15-03906...
  • Page 118 Electrical Cabinet (continued) MACHINE W/ SERIAL #’S OVERLOAD DESCRIPTION 8WT50074 OR HIGHER 15-04008 7 TO 10 AMP OVERLOAD RELAY 15-04009 16 TO 24 AMP OVERLOAD RELAY MACHINE W/ SERIAL #’S OVERLOAD DESCRIPTION BELOW 8WT50074 10-00670 6.0-8.5AMP OVERLOAD RELAY 15-00139 16-24AMP OVERLOAD RELAY 17-00076 Rev.D.8.2024...

  • Page 119: Mas 350 Bowl Assembly

    MAS 350 Bowl Assembly 17-00076 Rev.D.8.2024...
  • Page 120 MAS 350 Bowl Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. SEE LIST IN FIG. DRIVE & BOWL, MAS 350 15-03685 BOWL ONLY, MAS 350 15-00858 DOWEL PIN, 4MM X 14MM, HARDENED STEEL 15-03739 BLOCK, MAS 350 MOUNTING 15-02924 LEVER, LOCKING, MAS 350 15-03957 1/4”...

  • Page 121: Dual Safety Sensor (15-42360) & Upper Tool Holder (15-40036)

    Dual Safety Sensor (15-42360) & Upper Tool Holder (15-40036) 17-00076 Rev.D.8.2024...
  • Page 122 Dual Safety Sensor (15-42360) & Upper Tool Holder (15-40036) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03439 BODY, UPP. TOOL HOLDER, SAFETY SENSOR, WT 15-03650 SAFETY SENSOR, TURCK, NC 15-03649 SAFETY SENSOR, TURCK, NO 15-03206 CONTINUITY SPRING, 1 ¾ “, UNIVERSAL 11-00016 CONTINUITY GUIDE PIN H-3738...

  • Page 123: Quick Mount Assembly (15-40026)

    Quick Mount Assembly (15-40026) 17-00076 Rev.D.8.2024...
  • Page 124 Quick Mount Assembly (15-40026) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-02782 LOCKING AXLE, QUICK MOUNT, MULTI-SHUTTTLE, WT (-4) 15-01674 SHCS, M3 x 0.5 x 25, STEEL, BLACK OXIDE 15-02784 LEG LOCKING SIDE, QUICK MOUNT UPPER, WT (-4) 15-02785 LEG POSITION SIDE, QUICK MOUNT UPPER, WT (-4) H-3738 SHCS, M5 x 0.8 x 12mm, BLACK OXIDE 15-01601...

  • Page 125: Multi-Shuttle Assembly (15-40027)

    Multi-Shuttle Assembly (15-40027) 17-00076 Rev.D.8.2024...
  • Page 126 Multi-Shuttle Assembly (15-40027) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01870 SLIDE TABEL, MXS6, MULTI-SHUTTLE 15-02883 INSULATOR PLATE, MULTI-SHUTTLE 15-02881 ALIGNMENT PLATE, MULIT-SHUTTLE 15-02882 MOUNTING PLATE, MULTI-SHUTTLE 15-00305 FHCS, M4 X 0.7 X 16MM 15-01754 DOWEL PIN, ¼ “ X ½ “, HARDENED STEEL H-3871 SHSS, M5 X 0.4 X 12mm, BLACK OXIDE ALLOY STEEL H-3815...
  • Page 127 TIS-3 Assembly (15-41593) 17-00076 Rev.D.8.2024...
  • Page 128 TIS-3 Assembly (15-41593) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-00449 SHCS, M3 X 0.5 X 14MM, STAINLESS 15-01295 ROUND VINYL CAP BLUE 15-01296 ROUND VINYL CAP GREEN 15-01297 ROUND VINYL CAP RED 15-01298 ROUND VINYL CAP YELLOW 15-01585 COVER, BASE, TIS-2 15-01586 ROTATION HUB, TIS-2, -3 15-01587...
  • Page 129 TIS-3 Assembly (continued) 15-02997 BASE TOOL HOLDER, TIS-2 QUICK DISCONNECT, WT4E 15-03031 AIR CYLINDER 15-00286 TUBING 1/4" 15-00285 TUBING 5/32" 15-01754 DOWEL PIN, ¼” X ½”, HARDENED STEEL 17-00076 Rev.D.8.2024...

  • Page 130: Standard Lower Tool Holder (H-166-8)

    Standard Lower Tool Holder (H-166-8) ITEM NO. PART NUMBER DESCRIPTION QTY. H-166-9 BODY, COMMON LOWER TOOL HOLDER H-169-4 SHOE FOR LOWER TOOL HOLDER H-169-5 PIN FOR LOWER TOOL HOLDER H-169-6 LOWER TOOL WASHER 11-00041 LOCK CYLINDER 11-00042 BLACK LOCKING LEVER SERVICE ONLY 11-00191 SHCS, M16 MODIFIED 11-00199...

  • Page 131: Hydraulic Cylinder Main Assembly

    Hydraulic Cylinder Main Assembly 17-00076 Rev.D.8.2024...
  • Page 132 Hydraulic Cylinder Main Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-02889 HYDRAULIC CYLINDER, 8 TON, WT & OT (-4) 15-03072 7/16-20 x 1/4-18, 90 DEG ELBOW POSITIVE STOP SYSTEM ASSEMBLY 11-00271 824 CYL. INSULATION SHOE H-3804A 5/8 BOLT INSULATION H-3804B 5/8 BOLT INSULATION 15-03221 PRESSURE HOSE, .5”X 16 ¼”...

  • Page 133: Positive Stop System Assembly

    Positive Stop System Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-00116 POSITIVE STOP BASE PLATE 15-00115 POSITIVE STOP CLAMP PLATE 15-00117 POSITIVE STOP INNER TUBE 15-00683 ASSY, POSTIVE STOP SLOTTED TUBE 15-00119 POSITIVE STOP OUTER TUBE 15-00120 NUT, POSITVE STOP, 824+, WT & OT (-3) 15-00046 CET CONNECTING BAR 17-00076 Rev.D.8.2024...

  • Page 134: Vacuum Generator Assembly (15-43004)

    Vacuum Generator Assembly (15-43004) 17-00076 Rev.D.8.2024...
  • Page 135 Vacuum Generator Assembly (15-43004) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01325 FITTING: BUSHING BRASS 1/4 MALE NPT X 18 FEMALE NPT 15-03661 SHCS, M4 X 0.7 X 40MM H-5020 SWIVEL ELBOW, 90 DEG, 1/8 NPT X 1/4 TUBE 14-00638 AIR FITTINGS 11-00587 24V SOLENOID VALVE 11-00589...

  • Page 136: Air Manifold Assembly (15-03901)

    Air Manifold Assembly (15-03901) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03901 AIR MANIFOLD (FULL ASSEMBLY) 15-03371 VALVE, DUAL 3/2, PNEUMATIC 15-02857 VALVE, 3-POSITION SINGLE, PNEUMATIC 15-00285 1/4” DIA. AIR LINE 15-00552 5/32” FITTING PLUG 15-00286 5/32” DIA. AIR LINE 17-00076 Rev.D.8.2024...

  • Page 137: J-Frame, Abft Assembly Option (15-41870)

    J-Frame, ABFT Assembly Option (15-41870) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03255 J-FRAME, BOTTOM FEED TOOL, WT H-172-3 CLAMP PLATE, LEFT HAND H-172-4 CLAMP PLATE, RIGHT HAND 11-00319 SHCS, M6 X 1.0 X 20MM, STAINLESS 15-01393 LOCK WASHER, M6, DIN 127, ZINC 17-00076 Rev.D.8.2024...

  • Page 138: Hydraulic Reservoir Assembly

    Hydraulic Reservoir Assembly 17-00076 Rev.D.8.2024...
  • Page 139 Hydraulic Reservoir Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-00782 H.S. RESERVOIR TOP 15-00784 RESERVOIR WELDMENT 15-02166 DRAIN PLUG, O-RING BOSS ½ “ 15-00226 LEVEL GAUGE W/O THERMOMETER 15-00758 RETURN FILTER ASSEMBLY 15-01183 FITTING, STRAIGHT, 3/4" MALE 3 824 HYDRAULIC COOLER ASSEMBLY HYDRAULIC SUCTION FILTER ASSEMBLY 15-01185 FITTING, MJ-MP 90 8-12...

  • Page 140: Motor Pump Assembly

    Motor Pump Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-00077 MOTOR, 5 HP, 1800 RPM, 50/60 HZ, 208/440 V 15-01124 COUPLER 8.5 "A" PUMP / 4.75 LONG 15-01123 PUMP 824 HS 15-01143 FITTING, 90 ELBOW, 16 MALE 37 JIC O-RING 15-01142 FITTING, 90 ELBOW, 12 MALE 37, JIC TO MAILE O-RING 15-00062...

  • Page 141: Hydraulic Cooler Assembly

    Hydraulic Cooler Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-00783 BRKT, RESERVOIR COOLER MOUNT 15-01601 M6, WASHER, ZINC PLATED 15-01393 LOCK WASHER, M6, DIN127 ZINC 11-00319 SHCS, M6 x 1.0 x 20MM, STAINLESS 15-01132 COOLER, 824 H/S ECO 4 15-01147 MB-MJ 90 12-12 MALE BOSS TO MALE JIC 90 17-00076 Rev.D.8.2024...

  • Page 142: Hydraulic Manifold Assembly (15-03913)

    Hydraulic Manifold Assembly (15-03913) 17-00076 Rev.D.8.2024...
  • Page 143 Hydraulic Manifold Assembly (15-03913) 17-00076 Rev.D.8.2024...
  • Page 144 Hydraulic Manifold Assembly (15-03913) ITEM NO. PART NUMBER DESCRIPTION MANIFOLD BLOCK 15-04003 VALVE, 4/2, 4WE, 10 GA 4-WAY 2 POSITION 15-04004 VALVE, 4/3, 4WE 10 L 4-WAY 3 POSITION 15-01398 COUNTER BALACE VALVE 15-03778 CHECK VALVE, 5PSI, FC10-2 15-04002 PRESSURE TRANSDUCER, 0-5000PSI, 4-20MA 15-01197 SHCS, M6 X 40MM, STEEL, BLACK OXIDE 15-03782...

  • Page 145: Hydraulic Suction Filter Assembly

    Hydraulic Suction Filter Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01180 FITTING JIC MB-MJ 16-12 15-01163 FITTING JIC MB-MJ 16-16 15-02720 SUCTION ACCESS PLATE 15-01131 SUCTION FILTER 1” NUT STYLE 15-00781-1 1” X 4” PIPE NIPPLE 17-00076 Rev.D.8.2024...

  • Page 146: Return Filter Assembly (15-00758)

    Return Filter Assembly (15-00758) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-02715 CAP, FILTER ASSEMBLY RETURN 15-02714 RING, FILTER ASSEMBLY RETURN CAP 15-00888 HYDRAULIC FILTER ELEMENT 15-01183 FITTING MB-MJ 16-12 15-02537 FLANGE GASKET, FILTER RETURN ASSEMBLY 15-02629 BREATHER ELEMENT, FILTER RETURN ASSEMBLY 15-00212 BREATHER CAP 17-00076 Rev.D.8.2024...

  • Page 147: Service Tray Assembly

    Service Tray Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01294 PART BIN 7 X 4 YELLOW 15-01291 PART BIN 7 X 4 DARK BLUE 15-01299 PARTS TRAY HOLDER 15-01292 PART BIN 7 X 4 MEDIUM GREEN 15-01293 PART BIN 7 X 4 RED 11-00179 SERVICE TRAY ARM 11-00184...

  • Page 148: Section 8 - Decommissioning Your Machine

    SECTION 8 – DECOMMISSIONING YOUR MACHINE The decommissioning of a Haeger machine is a rare occurrence as older models themselves become 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.

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