Operating Instructions

Hardware Insertion Machine Introduction

Introduction
The Operating Controls Section of this
Hardware Insertion Machine Manual is second
in importance only to the Safety System Section
(Section 3). !
This section provides you, the operator, with all This symbol, appearing throughout
the information that you need to operate this this manual, means: Attention! Be
Hardware Insertion Machine safely and Alert! Your safety is involved.
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 section and in
NEVER wear anything that may
Section 1.
come into contact with the Upper
Your safety and productivity depend on it. Tool, Lower Tool or workpiece
(watches, rings, bracelets, etc.)

! Warning!
Never leave your foot on or
above the Down Footswitch
after you have completed each
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 and you intend to lower or
raise the Upper Tool Holder or
insert hardware.

4.1

Section 5: Operating Instructions

Operating Instructions
Operating Controls
Figure 4.1: All the controls for the
machine are within easy reach of the
operator.
This vertical bar represents
the On Switch on the
Machine’s Control Panel.
This circular symbol
represents the Off Switch.
4.2
Hardware Insertion Machine
Operating Controls
Note:
Except for the Down Footswitch, all
operating controls referred to in this section
are on the Control Panel located at the front
right side of the machine. (See Figure 4.2)
On Switch & Light
The On Switch is a momentary contact push
button switch with a light in it (See Figure 4.2)
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.
Off Switch
The Off Switch is used to shut the machine off
in all situations (See Figure 4.2)
It is a two position switch with a red mushroom
button. When it is pushed in, it latches, turns the
machine’s controls off and shuts down the
machine’s motor. When the button is pushed
in, 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, by pressing the green ON
switch.
Note:
Pushing the red mushroom button does
not turn off the touchscreen controller,
only motor and other controls.
 Operating Instructions
Hardware Insertion Machine Operating Controls

Figure 4.2: These Control Panels

contain most of the controls needed to
operate the machine.

4.3
Operating Instructions
Operating Controls
! Warning!
This is a keyed Selector Switch.
It has been provided to permit
strict supervisory control over
the use of the Conductive and
Non-Conductive Modes of
operation.
It is the supervisor’s
responsibility to evaluate each
operation to determine which
mode should be used for each
application. Once the supervisor
selects the mode of operation,
the supervisor must remove the
key.
Do not leave the key in the
switch!
The Conductive Mode
position on the Keyed
Selector Switch is on the
right and is represented by
this symbol.
The two straight lines form
a V and represent the
Footswitch. The arrow
indicates that the machine’s
Upper Tool will start moving
down when the Down
Footswitch is depressed. In
this mode, the Upper Tool
will complete one full stroke,
provided all operating
conditions are met.
4.4
Hardware Insertion Machine
Conductive/Non-Conductive Mode
Keyed Selector Switch
The Conductive/Non-Conductive Keyed Selector
Switch is a two-position selector switch (See
Figure 4.2) It requires a key. This enables the
supervisor to select either Conductive Mode or
Non-Conductive Mode of operation.
Conductive Mode
Conductive Mode is used to insert hardware into
conductive materials such as steel, stainless steel
and aluminum.
Run Mode Operation
When the Down Footswitch is depressed, the
Upper Tool Holder will go down. When the
Upper and Lower Tools make electrical contact,
the Hardware Insertion Machine will exert the
preset force, then reverse and go to the Up
Position (see Up Position on page 4.9)
If the Upper and Lower Tools encounter any
nonconductive material, such as fiberglass,
plastic, or some coated materials, the tools will
not make electrical contact. The Upper Tool will
immediately reverse and go up to the Up
Position. Once the upward travel starts, release
the Down Footswitch.
Setup Mode Operation
When the Down Footswitch is depressed, the
Upper Tool Holder will go down. When the
Upper Tool contacts a conductive workpiece,
the Hardware Insertion Machine will exert the
preset force and hold it until the Down
Footswitch is released.
 Operating Instructions
Hardware Insertion Machine Operating Controls

Non-Conductive Mode ! Caution!

The Non-Conductive Mode is used to insert Never press the Down Footswitch
hardware into nonconductive materials such as a second time in Non-Conductive
fiberglass, plastics and some coated materials. Mode when your hands are in the
Run Mode Operation area of the tooling.

When Run Mode is selected with Non-

Conductive Mode and the Down Footswitch is
depressed, the Upper Tool Holder will go down The Non-Conductive Mode
until the Upper Tool contacts the workpiece and position on the Selector
then stop. The Down Footswitch must then be Switch is on the left and is
released. When the Down Footswitch is represented by this symbol.
depressed a second time, the Hardware
Insertion Machine will exert the force for The two straight lines form
which it has been set and then return to the Up a V and represent the
Position. Release the Down Footswitch once the Footswitch. The arrow
upper tool starts to move up. indicates that the machine’s
Upper Tool will start moving
Setup Mode Operation down when the Down
When Setup Mode is selected with Non- Footswitch is depressed.
Conductive Mode and the Down Footswitch is The upper Footswitch
depressed, the Upper Tool Holder will go down. symbol indicates that the
When the Upper Tool contacts a nonconductive Upper Tool will only
workpiece, the Hardware Insertion Machine will complete the down part of
stop. No force will be applied. The Down the stroke when the Down
Footswitch must then be released. When the Footswitch is depressed. No
Down Footswitch is depressed a second time, force will be applied. When
the hardware Insertion Machine will exert the the Upper Tool stops, your
preset force and hold it until the Down foot must be removed from
Footswitch is released. the Down Footswitch.
The lower Footswitch
symbol indicates that the
Down Footswitch must be
depressed a second time to
exert the preset force.
This Footswitch is shown on
a yellow triangle to indicate
Caution.
Remember, when the
Down Footswitch is
depressed a second
time, it will exert the
force the machine has
been set for.

4.5
Operating Instructions
InsertionLogic Software
Figure 4.3: The Operations screen of
the Insertion Logic software enables
you to control all the major machine
settings.
! Caution
Touch buttons on the Touchscreen
only with your finger. Do not use
any other object or damage to the
Touchscreen could occur.
Figure 4.4: Use the +/– buttons to
change the values in the adjacent box.
4.6
Hardware Insertion Machine
Using the InsertionLogic
Software
The Hardware WindowTouch Insertion Machine
is equipped with a computer running the
InsertionLogic software. This computer
controls most of the machine’s settings and
functions and is equipped with a Touchscreen.
You will use the Touchscreen to enter
information into the computer.
Using the Touchscreen
The Touchscreen is the main method of entering
information into the software and controlling the
computer.
All of the buttons on the Touchscreen have been
made large to make it easier to make contact,
even with gloves on.
To use a button on the Touchscreen, press
firmly on the center of the button.
Entering Information and Changing
Values
The InsertionLogic software provides several
methods of entering most values.
Using the +/– Buttons
Next to many of the values on the Touchscreen
are + and – buttons (See Figure 4.4) Pressing
the + button quickly will increase the value in
the box next to the button by a small increment.
Pressing and holding the + button for more than
a second will increase the value by a larger
amount. The – button works the same way to
decrease the value in the box.
 Operating Instructions
Hardware Insertion Machine InsertionLogic Software

Display Window

Range Selector

Keypad

Buttons

Figure 4.5: The Keyboard screen

enables you to enter specific values.

Using the Keyboard Screen

You can use the Keyboard Screen to set many
of the values required by the InsertionLogic Example:
software. To set a force of 4000 pounds,
If you touch any of the white boxes that contain touch the force box. When the
values (for example, the box next to Force), the Keyboard Screen appears, if a
Keyboard Screen will appear (See Figure 4.5) value is already set, clear it by
touching the Clear button.
To enter a specific value, touch the numbers or
letters. Once the value is displayed correctly in Touch the keypad buttons for
the display window, touch the OK button. 4000. When the correct value
shows in the display window,
To clear the contents of the display window,
touch the OK button. If you make
touch the Clear button.
a mistake while typing, you can
To remove the last character that you entered in delete the last character by
the display window, touch the Back button. touching the Back button.
Many of the keyboard windows also have a You can also touch the fourth box
range selector immediately underneath the in the range selector. The display
display window. You can touch one of the boxes window will change to 4000
between the Minimum and Maximum boxes to pounds.
choose one of the preset values.
Touch the OK button when
The up and down arrows next to the display finished.
window are used to scroll through more than
three lines of information. You will rarely need to
use these.

4.7
Operating Instructions
InsertionLogic Software
Figure 4.6: The Warmup screen will
appear automatically after turning on
the machine.
Figure 4.7: Touch the white box to
enter your Name.
Figure 4.8: Type in your password using
the keypad. Touch the OK button when
completed.
4.8
Hardware Insertion Machine
Getting Started
The InsertionLogic software will start
automatically when you turn the machine on.
1. Turn on the machine by turning the main
disconnect switch to the ON position.
2. The Haeger startup screen will be displayed
on the monitor. Wait until the Warmup
Screen appears (See Figure 4.6) The timer
will count down. You can cancel this
warmup by touching the cancel button on
the screen if the machine has already been
on long enough (depending on the
temperature where the machine is located).
Note:
You can change the warmup time in the
Maintenance Screen. See Page 4.17
for more details.
3. Once the warmup is complete the Log In
box will appear. You will need to login to the
software (See Figure 4.7) by touching the
white box next to Name. The Keyboard
Screen will appear. Enter your Name by
touching the correct letters and/or numbers.
When the Name is correct in the display
window, touch the OK button and the
Password screen will appear.
4. Enter your Password by touching the
correct letters and/or numbers. When the
Password is correct in the display window,
touch the OK button.
Your Name and Password determines your
access level.
Logging in with an Basic Operator password,
you will be able to run the machine, but you will
not be able to set or change any values.
Logging in with an Qualified Operator
password, you will be able set and change items
that the Administrator gives you access to.
Logging in with a Maintenance level password,
you will be able to set and change most of the
settings.
 Operating Instructions
Hardware Insertion Machine InsertionLogic Software
Logging in with an Administrator password gives
you access to the entire program, including
administrative routines. See Page 4.12 for more
details.
Once you have logged in to the InsertionLogic
software, the Operations Screen will appear. You are
now ready to use the software and the machine.

The Operations Screen

Force
The Force is the amount of force that will be
applied between the Upper and Lower Tools during Figure 4.9: You will set most of the
the hardware insertion cycle. machine options on the Operations
The force can range from 1000 pounds to 16000 Screen.
pounds (8 tons).
Check the specifications for your fastener to
determine the appropriate force to use.

Dwell Note:
An increased Dwell setting should be
The Dwell is the length of time that the force is
used when inserting fasteners into
applied between the Upper and Lower Tools.
materials such as stainless steel.
It can range from 0.0 seconds to 3.0 seconds.
If you set the Dwell to 0.0 seconds, the Upper Tool
will lower, apply the Force and return to the Up
Position.
Note:
If you set the Dwell value greater than 0.0 seconds, The Up value is measured as a
the Upper Tool will lower and apply the Force. It percentage of the total cylinder stroke.
will then continue applying the force for the length It will vary depending on the size of the
of time set by the Dwell value. Upper and Lower Tools. If the Up value
is set to 0%, the Upper Tool will return
Up Position to its minimum height after applying a
The Up value controls the Up Position of the Upper force. Setting the Up value to 100%
Tool. This is the position the upper tool returns to will cause the Upper Tool to return to
after applying the force. The Up value is measured the Heighest possible point.
as a percentage of the total cylinder stroke. It will
vary depending on the size of the Upper and Lower
Tools. If the Up value is set to 0%, the Upper Tool
will return to its minimum height after applying a
force. Setting the Up value to 100% will cause the
Upper Tool to return to the Heighest possible point.

4.9
 Operating Instructions
InsertionLogic Software
Figure 4.10: The Tooling Protection
System (TPS) can be turned off by
touching the On/Off button. To set
TPS, touch the Set TPS button.
Figure 4.11: The Batch section of the
Operations Screen counts the number
of Fasteners to Insert and the number
of Completed Parts.
4.10
Hardware Insertion Machine
The TPS Controls
The Tooling Protection System (TPS) is
designed to protect both the tooling and the
workpiece from damage. It works with
Haeger’s patented Safety System. When
properly set up, the TPS detects when the force
is about to be applied to insert the hardware. If
the position detected by the TPS is not correct,
the Upper Tool will retract without exerting the
insertion force. The TPS can also be turned Off
and Haeger’s patented Safety System will
remain fully operational. It is recommended,
however, that the TPS be used for all hardware
insertion operations.
For more information about setting the TPS
controls in the Insertion Logic software, See
Page 4.38
The Batch Counter
The lower portion of the Operations Screen (See
Figure 4.11) is used to keep track of:
• the number of pieces of hardware remaining to
be inserted (count)
• the total number of workpieces completed
(batch)
Fasteners to Insert
This counter indicates the number of fasteners
remaining to be inserted. The symbol next to the
number shows a fastener and a minus sign (–),
indicating that the count will decrease by one
every time the force is applied between the
Upper and Lower Tools.
When the count reaches zero, the Fasteners to
Insert Counter resets and the Completed Parts
value increases by one. If you need to change
the count, you can use the +/– buttons or touch
the number in the box and use the Keyboard
Screen.
 Operating Instructions
Hardware Insertion Machine InsertionLogic Software

Completed Parts
This counter shows the total number of
workpieces completed during the current run
of parts. It increases by one each time the Figure 4.12: The Batch section of the
number of fasteners to insert reaches zero. The Operations Screen counts the number
Completed Parts value (Batch Counter) can be of fasteners to insert and the number
changed using the +/– buttons or touch the of completed parts.
number in the box and use the Keyboard
Screen..

Vacuum and Eject Fastener

The Vacuum button in the Operations Screen
is used to turn the vacuum for the Modular
Autofeed System (MAS) on and off (See
Figure 4.13). With the system ON the vacuum
generator will turn on when the down foot
pedal is pressed. After the completed insertion
it will turn off.
The Eject Fastener button is used to manually
Figure 4.13: The Vacuum and Eject
eject a fastener from the Modular Autofeed Fastener section of the Operations
System (MAS) to the Insertion tooling. Screen enables the operator to manually
The MAS is an optional feature on all Haeger Eject a fastener and turn the Vacuum for
Hardware Insertion Machines. If you do not the fastener on and off.
have a MAS installed, these buttons will be
disabled (they won’t do anything).
For more information about the operation of
the MAS, see the Modular Autofeed System
section of your manual.

4.11
Operating Instructions
InsertionLogic Software
Figure 4.14: The Run / Setup toggle
changes the machine’s operating
mode.
Figure 4.15: The Administration
Button will appear on the Operations
Screen when you log in with an
Administration password.
Figure 4.16: You can control all of the
administrative functions in the
Administration Screen.
4.12
Hardware Insertion Machine
Run/Setup Toggle
The Run/Setup Toggle (See Figure 4.14),
controls whether the machine is running in Run
or Setup mode. See the Conductive/Non-
Conductive Keyed Selector Switch description
on Page 4.4 for how the Hardware Insertion
Machine operates in Run and Setup Modes.
Run Mode
The Run Mode is the normal operating mode for
the Haeger Hardware Insertion Machine and will
be used to insert all hardware.
Setup Mode
The Setup Mode is used to setup the Tool
Alignment.
Administrative Routines
When you login with an administrative
password, the Administration button (See Figure
4.15) will appear on the Operation Screen. If
you touch the Administration button, the
Administration Screen appears (See Figure 4.16)
The administrative routines are used to:
• set the passwords
• change the language and the units of
measurement
• calibrate the touch screen
• set and change PLC functions.
• back up programs or retrieve programs from
disk.
 Operating Instructions
Hardware Insertion Machine InsertionLogic Software

Passwords
To Add or Delete a Password
1. Login as an administrator.
If someone else is logged in as a operator,
touch the Maintenance button and then the
Logout button, See Page 4.17. Login again
with the Administration name and password,
then enter Administrative Routines by
pressing the Administration button.
2. Touch the Passwords button.(See Figure
4.16)
3. To add a password, touch the New button.
Type the new name using the keyboard, then
Figure 4.17: You can control all of the
enter the new password and touch the OK
password functions in the password
button. You will now have to reenter your
Screen.
password again, then select the security
level. Touch the OK button when finished.
Choose the security level.
1 Administrator
2 Maintenance
3 Qualified Operator
4 Basic Operator

4. To delete a password, touch that password

and then touch the Delete button.
5. When finished, touch the OK button to
return to the Administration screen. Press
the OK button again to return to the run
screen. It is recommended to log out and
have the operators login with their
passwords.

4.13
Operating Instructions
InsertionLogic Software Hardware Insertion Machine

Level 3 Setup
The level 3 setup is provided to give the
ability to change certain machine/program
parameters to certain operators. A level 4
operator does not have access to change any
critical or quality settings.
1. Login as an administrator and enter the
Administration screen.
2. Press the password button.
3. Press the Level 3 Setup button.
4. On Level 3 Setup screen (See Figure 4.18)
Figure 4.18: You can control what all level You can select which functions the level 3
3 operators have access to by checking the operator will be able to control. Any operator
white box in front of the control. with a level 3 security level will have the
same control.
NOTE:
These settings can not be set for each
level 3 operator. These changes will be
for all level 3 operators.

Options
To change the Language, Force, TPS
sensitivity, and enable the Require Part
Complete screen.
1. Login as an administrator.
2. Press the Administration button.
3. Touch the Options button.
TPS Sensitivity
To change the TPS sensitivity, touch the
white box and a keyboard will appear
Figure 4.19: The Option screen allows you allowing you to make changes. A lower
to change TPS Sensitivity, select your number will make the TPS more sensitive
Language, limit the Max Force and enable and a higher number will make the TPS less
the Required Part Complete Screen. sensitive.

4.14
 Operating Instructions
Hardware Insertion Machine InsertionLogic Software

Language
Use the scroll arrow to select your
language, then press the OK button.
Note:
The Language will not change until
InsertionLogic is restarted. See
Page 4.34 for proper shut down
procedures.

Maximum Force
Figure 4.20: Use the scroll arrow to
To change the Maximum Force the select your Language.
machine will reach, check the small
white box, then touch the white lbs box
to change the setting.
NOTE:
No matter what force is selected on
the run screen it will not be able to
be changed to anything higher
then what is set in the Max Force
Screen.

Required Part Complete

The Required Part Complete Screen, if
the box is checked, will lock out the
ram after a part has been completed in
the Auto Mode . The operator will then Figure 4.21: The Part Complete
have to touch the touchscreen, screen will appear when the part has
confirming the part is complete to been completed in the Auto Mode.
proceed. (See Figure 4.21)

4.15
Operating Instructions
InsertionLogic Software
Note:
PLC values are critical settings
that are set at the factory. Do
not change any of these values
unless instructed to do so by a
qualified Haeger Technician.
Figure 4.22 PLC values are critical
settings that are set at the factory. Do
not change any of these values unless
instructed to do so by a qualified
Haeger Technician.
4.16
Hardware Insertion Machine
Change PLC Values
Pressure Sensor, Top Of Stroke, and Slow
Down Point can be changed by pressing the
Change PLC Values button. These setting
are set at the factory and should not be
changed unless instructed to do so by a
qualified Haeger Technician.
Pressure Sensor Value
This value is the setpoint for the Pressure
Transducer. When the pressure reaches this
setpoint the ram will return up.
Top Of Stroke Value
This value is the setpoint that the ram must
travel to under an error condition. This value
represents the CET (Cable Extension
Transducer) at full up travel of the ram.
The CET is a transducer that is mounted on
top of the machine frame and connected to
the top of the Ram by a cable.
Slow Down point
This is an adjustable set point to control ram
speed at a certain position. When the Ram
reaches the setpoint in this box, it will slow
down for the rest of the stroke.
 Operating Instructions
Hardware Insertion Machine InsertionLogic Software

Maintenance
When the Maintenance Button is touched (See
Figure 4.23), a dialog box will appear asking if
you want to save changes to the program. When Figure 4.23: Touch the Maintenance
this box appears, yes should always be pushed button to enter the Maintenance
to ensure all program information is saved. after Screen.
touching the yes button (See Figure 4.24) the
Maintenance Screen will appear.

Maintenance Screen
The Maintenance screen is used to:
• Set the warmup time
• Check the amount of time before routine Figure 4.24: When this box appears,
maintenance of the oil system, filters and Yes should always be pushed to
upper tool holders ensure all program information is
saved.
• Shut Down
• Logout

Setting the Warmup Time

The Warmup Time can be increased or
decreased in the Maintenance Screen by
touching the white box next to Warmup Time
and using the keypad to set the time.(See Figure
4.25)
If the shop where the machine is located is very
cold, this value should be increased to ensure
the machine is fully warmed up before use.

Figure 4.25: The Maintenance

Screen contains count down timers for
routine maintenance and Warmup
Time.

4.17
Operating Instructions
InsertionLogic Software Hardware Insertion Machine

Routine Maintenance
Your Window Touch Hardware Insertion
Machine should have its oil, filters and upper
tool changed/cleaned periodically. The
Maintenance timers will count down. When they
reach zero, it is time to service the specified
item.
When any of the Maintenance Timers have
reached zero the Maintenance button on the
Operation Screen will flash and continue to flash
until a new value is entered for the maintenance
item. (See Page 6.1 for recommended
maintenance intervals). The values are adjustable
depending on machine use and shop condition.

Shutting Down
Touch the Shut Down button to shut down the
machine. For more information about shutting
Figure 4.26: The Maintenance
down the machine, See Page 4.34
Screen contains count down timers for
routine maintenance.
Logging Out
You can log out from the InsertionLogic
software without shutting down by touching the
Log Out button. This will return you to the
Login Screen.

When you are finished with the Maintenance

Screen, you can press the OK button to return
to the Operations Screen.

4.18
 Operating Instructions
Hardware Insertion Machine InsertionLogic Software

Help
Pressing the Help Button in the Operations Screen
will bring you to the Help Screen. The Help Screen
is designed to aid in troubleshooting. Through this
screen we are able to check Inputs and Outputs of
the PLC program and view critical setpoints and
values.

Diagnostics
Pressing the Diagnostics button will bring you to Figure 4.27: The Help Screen
the Diagnostic screen. There are four tabs on the contains the Diagnostic information.
top of the screen which can be selected to view X
inputs, Y outputs and Internal Registers. The Other
tab is used to check setup values for the Top of
Stroke, Slow down point, TPS, Pressure Value and
CET readings. None of these settings can be
changed. These are for Troubleshooting
information only.

X inputs screen:
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.

Y Outputs screen:

These are Outputs from the PLC to various points

on the board to control Relays, Air Cylinders, Figure 4.28: The Diagnostic Screen
Modular Auto Feed (MAS), and other functions.
contains inputs and outputs from the
Registers: PLC and critical setpoint information.

These are internal program registers inside the PLC

program.
Other:

This tab is used to check setup values for the Top

of Stroke, Slow down point, TPS, Pressure Value
and CET readings. None of these settings can be
changed. These are for Troubleshooting
information only.

Figure 4.29: The Other Screen in the

Diagnostic screen contains critical
setpoint information.

4.19
Operating Instructions
Setting Up A Program
Figure 4.30: Touch the Programs
button to start setting up a program.
Figure 4.31: The Programs screen
lists all the saved programs.
Figure 4.32: The Setup Program File
screen is used to set information for
each MAS/Tool station.
Note:
On the Window Touch, MAS/Tool station 1 is
the default location for Modular Autofeed
System (MAS) operation. If Autofeed Tooling is
to be used, the corresponding fastener must
be programed at MAS/Tool 1.
4.20
Hardware Insertion Machine
Using Programs
One of the most useful features of the
InsertionLogic software is the ability to store
and recall programs. When you save a program,
you are saving all the setup values: Force,
Dwell, Up Position, TPS settings, Fastener
Detection and Fastener Length. These programs
can be named so that they can be easily recalled.
Setting up a Program
Before you can use a program, you will need to
set one up with all the settings needed to
control the machine.
1. Touch the Programs button on the
Operations Screen (See Figure 4.30)
Note:
The software will ask you if you would
like to save the current program. When
this box appears, Yes should always be
pushed to ensure all program
information is saved.
2. The Programs Screen will appear (See
Figure 4.31) Touch the New button.
3. The Keyboard Screen will appear. Type in a
program name and touch the OK button.
The name should be less than 10 characters
long.
4. Next the Setup Program File screen will
appear. (See Figure 4.32) In this screen, you
will select the type of fastener and the
quantity for each station.
5. Choose a MAS/Tool station from the
numbered boxes at the top of the screen.
6. To select the type of fastener for the MAS/
Tool station you selected, touch the white
box for Fastener Type.
7. To choose the fastener manufacturer, touch
the name of the manufacturer at the top of
the screen. Only those fasteners from that
manufacture will be displayed.
 Operating Instructions
Hardware Insertion Machine Setting Up A Program

8. To choose the material type, press the

Change Material button.
9. To choose the fastener type, choose from
the Nut, Stud or Standoff buttons on the
left of the screen. Only those fasteners will
be displayed.
10. To Choose the Fastener Size, select the
specific thread size or select the Show All
to show all sizes of the fastener type
selected.
11. To choose the specific fastener to be Figure 4.33: The Fastener Types
inserted, touch the white box of the desired Screen list the most common nuts,
fastener. The arrow on the right side of the studs and standoffs..
screen can be used to scroll through the
different fasteners. Touch the OK button
when finished.
Note:
You can also touch the Find button to
search for a specific fastener. The
program will use the first part of
whatever you enter to search for. For
example, if you touch the Find button
and enter S-2, the program will list all
fasteners with an S-2 in their name. In
this example, the program would list
any fastener with an S-256 or CLS-
256, but not S-348 or CLS-632.
OR
To create a Customized Fastener and Figure 4.34: Selecting the specific
Material. thread size of the fastener at the top
Select Other as the Manufacturer at the of the screen, will only show fasteners
top of the Fastener Types Screen. with that thread size in different dash
Press the New button. lengths.

A Keyboard Screen will appear. Enter the

Size of the fastener and touch the OK
button.
Enter the sheet material to be associated
with this fastener and touch the OK button.
Enter the force to be used with this
fastener and sheet material and touch the
OK button.

4.21
Operating Instructions
Setting Up A Program Hardware Insertion Machine

12. The Select A Tool Type screen will now

appear. Select the Type of tooling to be used
to insert the fastener.
Note:
Not all tools will be available to use with
all fasteners. Only those that can be
used with the fastener will be shown. If
you choose a tooling type that has
more than one tool option, you will need
to choose the specific tool(s).
13. Press the OK button.
14. The Setup Program File screen will now be
shown. Enter the Customer name and
Figure 4.35: Choose the type of Customer Part # by touching the white box
tooling you will be using to insert the next to each. Adjust the Force, Dwell and Up
fastener in the MAS/Tool station you position as necessary, in the same manner.
are programing.
Note:
Some tool choices will leave the
corresponding boxes empty.

Figure 4.36: If more than one tooling

option is available you will need to
select the specific tool.

4.22
 Operating Instructions
Hardware Insertion Machine Setting Up A Program

Program Notes
15. Notes such as specific setup instructions
can be entered for a part in the Notes
section. Touch the Notes button and the
Program Notes keyboard screen will appear.
Once finished typing your notes, touch the
OK button. The Program Notes will be
displayed on the Program Screen when the
program is highlighted.
16. Repeat the steps for the other 3 stations
by touching the numbered boxes at the
top for the other MAS/Tool stations. You
will also notice that each station is color Figure 4.37: Use the keyboard screen
coded. to enter Notes. The Notes will appear
on the Program Screen when the
MAS/Tool 1 = Green program is highlighted.
MAS/Tool 2 = Red
MAS/Tool 3 = Yellow
MAS/Tool 4 = Blue
There are also four bins supplied to hold
fasteners. These are color coded to match
the MAS/Tool stations to ensure the operator
is inserting the correct fasteners in the
correct MAS/Tool stations.
17. After all the stations have the correct
fasteners selected, you must now input the
correct amount of fasteners to be installed at
each MAS/Tool station. Enter the Total
amount of fasteners required for this part by
touching the white box Total Fasteners per
Part. The keyboard screen will appear.
18. To enter the Total Fasteners for each MAS/
Tool station. Touch the white box next to
Fasteners for this MAS. The keyboard
screen will appear. Figure 4.38: Enter Total Fasteners
per Part and Fasteners for this MAS at
the bottom of the Setup Program File
screen for each MAS/Tool station you
will be using.

4.23
Operating Instructions
Setting Up A Program Hardware Insertion Machine

More Screen
19. Touch the More button on the bottom
of the Program Screen and the More
Screen will appear. Here you can
adjust TPS Sensitivity and enable
Fastener Detection or Fastener Length
for each MAS/Tool station where you
are running Autofeed tooling. See
Page 4.35 for more information on
Fastener Detection and Fastener
Length. There are also two areas to
store information for MAS
Figure 4.39: In the More screen you Vibration setting and MAS Eject Time.
can adjust TPS Sensitivity and enable These boxes are followed by a yellow
Fastener Detection or Fastener asterisk which indicates these values
Length for each MAS/Tool station are for operator information only and
where you are running Autofeed not used by the computer or program.
Tooling.
Select Part Image
20. In the More Screen you can select a
JPEG picture of your part. This is a
useful tool that will show the operator
where each fastener goes and how
many to insert. Click on the white box
above Part Image. This will bring up a
listing of the pictures you have saved.
If you take a JPEG picture of the part
you can load it on a floppy and insert
it into the floppy drive on the front of
the computer, then select retrieve
from disk. This will pull the picture
Figure 4.40: The Select An Image files from your disk and save them to
screen is used to store and retrieve the program. When finished click
JPEG images from the floppy drive in OK. This will bring up the more
the front of the computer cabinet. screen. Click OK to return to the
program screen.

Note:
When saving a picture file you will need to
rename it. Do Not include any spaces in the
file name, this will cause an error “Command
Contains Unrecognized Phrase / Keywords”.

4.24
 Operating Instructions
Hardware Insertion Machine Setting Up A Program

Teaching Sequence
21. On the bottom of the window in the
program screen is the Teach Button. This
will bring up the Teach Screen. Here is
where you enter the sequences for the
machine to operate. When you first open the
screen the page will be blank. By pressing
the NEW button a new sequence will appear.
By touching the boxes you can change the
MAS/Tool station for a sequence, the
amount of fasteners you wish to install in the
MAS/Tool station, and the check box for the
TPS. If checked, this will automatically turn
on the TPS for the MAS/Tool station. You
can add as many sequences as you wish by
pressing the NEW button. To delete a Figure 4.41: The Teach Program
sequence, highlight the sequence and press Screen is used to create sequences
the Delete Button. When finished writing the for each MAS/Tool station.
program, press the OK button.
Insertion Map
1. To add a picture of your part for each
sequence, highlight the sequence number
then touch the Insertion Map button.
2. When the Insertion Map screen first appears
it will be blank. Click on the white box for
Part Image.
3. The Part Image screen will appear. (See
Figure 4.40) Here you can select from the
list of JPEG pictures already loaded, or you
can insert a disk in the floppy drive in front
of the computer and click retrieve from disk.
4. To select the locations on the part where you
need to insert the fasteners, touch the areas
on the part picture where you would like
these fasteners to be inserted then click the
OK button. Figure 4.42: The Insertion Map
5. Repeat this process until all sequences have Screen is used to select where each
a picture attached. Click the OK button on fastener is to be inserted for each
the screen to return to the setup program sequence.
screen. Click the OK button to return to the
programs screen.
6. The program you have just created will be
highlighted. If this is the program you would
like to run, click the OK button.

4.25
Operating Instructions
Selecting A Program Hardware Insertion Machine

Select Stored Programs.

1. Touch the Programs button on the
Operations Screen.
The software will ask you if you would like
to save the current program. When this box
appears, Yes should always be pushed to
ensure all program information is saved.
2. The Programs Screen will appear. Touch the
program you want to load (See Figure 4.43)
Use the scroll buttons (left and right, up and
down) to move through the programs and
their settings.
Figure 4.43: The Programs Screen is
3. Once you have selected the program that
where you can select which program
you want to load, touch the OK button to
you would like to run.
return to the Operations Screen.
Setup Summary screen.
Once you select a program the Setup
Summary screen appears. This screen
shows a quick snapshot of what tools are
needed by part number, the MAS air eject
time and Vibration settings and what
fasteners are to be used for each MAS/Tool
station. This screen is very useful for the
operator to set up the machine prior to
running the program. Touch the OK button
when finished.

Figure 4.44: The Setup Summary

Screen is a quick snapshot of tooling
required, fastener size, and MAS
settings for each MAS/Tool station.

4.26
 Operating Instructions
Hardware Insertion Machine Changing A Program

Changing an Existing Program

You can change an existing program if you find
that some of the values or information needs to
be adjusted.
1. Touch the Programs button on the
Operations Screen.
The software will ask you if you would like
to save the current program. When this box
appears, Yes should always be pushed to
ensure all program information is saved.
2. The Programs Screen will appear (See
Figure 4.45) Touch the program that you
want to change.
3. Touch the Change button. The Setup
Program File screen will appear. Change any
information that needs to be modified.
4. When you are finished, touch the OK
button. Touch the OK button again to return
to the Operations Screen. Figure 4.45: Touch the program that
you want to change.
Note:
You can also save any changes you
have made to a program on the
Operations Screen by touching the
white box above Current Program on
the Operation Screen and then
touching the Save button.

4.27
Operating Instructions
Conductive Mode Setup
! Warning!
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.
4.28
Hardware Insertion Machine
Conductive Mode Setup Procedure
Note:
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, call your Haeger Distributor.
Getting Started -
1. Use an existing program by touching the
Programs button and selecting the
appropriate program. For more information
about selecting programs, See Page 4.26
2. Select the proper tools for this application
and install them in the Upper and Lower Tool
Holders, See Section 2 Installation for
detailed instructions on installing Tooling.
Ensure the correct tool is in each station of
the Turret tool. Green is station one, Red is
station two, Yellow is station three and Blue
is station four.
3. Have your Supervisor use the key to set the
Conductive/Non-Conductive Switch to the
Conductive position.
 Operating Instructions
Hardware Insertion Machine Conductive Mode Setup

Checking the Up Travel & Insertion

1. Keep your hands away from the tooling area.
Without positioning the hardware or
workpiece for insertion, depress the Down
! Warning!
Foot switch and complete one stroke of the Never leave your foot on or
machine. above the Down Footswitch
after you have completed a
2. Check the position where the Upper Tool
stopped. cycle of the machine. Remove
it from the Down Footswitch.
Is it adequate to permit the workpiece to be
Keep your feet away from the
positioned easily while fasteners are
Down Footswitch until your
installed?
hands are clear of the tooling
If not, adjust the Up Position accordingly. If area.
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 by positioning the hardware and
workpiece and depressing the Down Foot
switch.
4. Examine the insertion.
Is the hardware properly seated?
Is the workpiece deformed? ! Warning!
Adjust the insertion force accordingly and Ensure proper tool alignment
insert another fastener. before attempting to make an
5. Repeat this process for the other tool insertion.
stations.
6. Once the hardware is properly inserted Set
TPS for each Fastener. See Page 4.38 for
detailed instructions on setting the TPS.

4.29
Operating Instructions
Non-Conductive Mode Setup
! Warning!
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.
4.30
Hardware Insertion Machine
Non-Conductive Mode Setup Procedure
Note:
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, call your Haeger Distributor.
Getting Started -
1. Use an existing program by touching the
Programs button and selecting the
appropriate program. For more information
about selecting programs, See Page 4.26
2. Select the proper tools for this application
and install them in the Upper and Lower Tool
Holders, See Section 2 Installation for
detailed instructions on installing Tooling.
Ensure the correct tool is in each station of
the Turret tool. Green is station one, Red is
station two, Yellow is station three and Blue
is station four.
3. Have your Supervisor use the key to set the
Conductive/Non-Conductive Switch to the
Non-Conductive position.
 Operating Instructions
Hardware Insertion Machine Non-Conductive Mode Setup

Checking the Up Travel & Insertion

1. Keep your hands away from the tooling area.
Without positioning the hardware or workpiece
for insertion, depress the Down Foot switch. ! Warning!
The Upper Tool Holder will move down, the Never leave your foot on or
Upper and Lower Tools will contact and stop.
above the Down Foot switch
Release the Down Foot switch. Depress the after you have completed a
Down Foot switch a second time. The machine cycle of the machine. Remove
will immediately apply the force, and the Upper it from the Down Foot switch.
Tool will return to the Up position. Keep your feet away from the
2. Check the position where the Upper Tool Down Foot switch until your hands
stopped. are clear of the tooling area.
Is it adequate to permit the workpiece to be
positioned easily while fasteners are installed?
If not, adjust the Up Travel Control accordingly.
If an adjustment is necessary, check the new
setting by depressing the Down Foot switch.
The Upper Tool will move down, the Upper and
Lower Tools will contact and stop. Release the
Down Foot switch. Depress the Down Foot
switch a second time. The machine will
immediately apply the force to the Lower Tool,
and the Upper Tool will return to the set Up
! Warning!
position. NEVER press the Down Foot
Repeat this step until the Up position is switch a second time in Non-
acceptable. Conductive Mode when your
hands are in the tooling area.
3. Keep your hands away from the tooling area.
Position the hardware and workpiece for
insertion. Insert the first piece of hardware by
depressing the Down Foot switch, releasing the
Down Foot switch and then depressing it a
second time.
4. Examine the insertion.
Is the hardware properly seated?
Is the workpiece deformed?
Adjust the insertion force accordingly and insert
another fastener.
5. Repeat this process for the other tooling stations.
6. Once the hardware is properly inserted Set TPS
for each Fastener. See Page 4.38 for detailed
instructions on setting the TPS.

4.31
Operating Instructions
Program Operation
Figure 4.46: The top of the Operation
Screen is the Auto Run button. When
in Auto Run Mode the button will turn
to a Stop Button.
Figure 4.47: The Part Image screen
shows the location and sequence of
the fasteners to be inserted.
Figure 4.48: The Part image screen
will change colors to coincide with the
MAS/Tooling station.
4.32
Hardware Insertion Machine
Running a Program
1. Once you have selected a program the Run
Screen will be displayed. To start the
program in auto run, press the Auto Run
button at the top of the screen. (See Figure
4.46)
2. This will bring up the first sequence in the
program. Each fastener location will be
displayed by a colored dot matching the tool
station along with a number to show the
sequence of the fasteners to be installed.
(See Figure 4.47)
3. Once the first fastener has been installed, the
second fastener to be installed will start
flashing. Once all fasteners have been
installed in the first sequence/station, the
program will sound a loud beep informing
the operator to change tool stations.
4. The program will now switch to show
where and how many fasteners are to be
installed in the second sequence/station.
Notice the color code has also changed to
red to coincide with station number two.
5. During the part run at the bottom of the
screen, the fastener part number and
complete part total will be displayed.
6. To escape out of the picture screen there is a
Hide Button. Pressing this button will take
you back to the run screen. To go back to
the picture screen, Click on the Show Button
on the run screen. (See Figure 4.49)
7. Any changes you make in the run screen
will be saved in the program, such as force,
dwell, up travel, etc.
8. When finished installing the correct amount
of fasteners in the MAS/Tool station, the
counter will sound an audible beep to let the
operator know it’s time to go to the next
MAS/Tool station. The screen at the top will
also change to the color of the next MAS/
Tool station.
 Operating Instructions
Hardware Insertion Machine Program Operation

9. When station number two fasteners have

been installed, the program will continue to
the next station. This process will continue
until all the fasteners have been installed.
10. After the part is complete, the Part complete
screen will appear, if it has been selected in
the Administration Screen. See Page 4.15.
This will lock out the ram and can only be
reset by the operator touching the screen.
This is an additional step the operator must
take to help insure the part has been
completed. (See Figure 4.50)
11. Once the part complete screen has been
reset, the operation will start over with the Figure 4.49: When you hide the Part
next part. Image Screen, the Operation screen
will now have a Show Button
displayed.

Figure 4.50: The Part Complete

screen will appear when all the
fasteners have been installed. This will
lock out the ram and will have to be
reset before running the next part.

4.33
Operating Instructions
Shutting Down
Figure 4.51: Touch the Maintenance
button on the Touchscreen.
Figure 4.52: Touch the Shut Down
button on the Touchscreen.
Figure 4.53: After confirming the shut
down, the software will display this
screen while shutting down.
Figure 4.54: Do not turn off the
machine’s power until the final shut
down screen is displayed
4.34
Hardware Insertion Machine
Shutting Down the Hardware Insertion
Machine
Note:
Follow this shut down procedure
whenever you turn off the machine. If
you do not, the Insertion Logic software
may not function properly and/or data
may be lost.
1. Touch the Maintenance button on the
Touchscreen (See Figure 4.51)
2. Touch the Shut Down button on the
Touchscreen (See Figure 4.52)
3. The software will ask you if you are sure
that you want to shut down. Touch the Yes
button. After confirmation, the application
terminates and displays: Please
Wait...Shutting Down Haeger Insertion
Logic (See Figure 4.53)
Then the final screen appears and displays:
Please power down the machine now. (See
Figure 4.54)
4. Turn of the machine by turning the main
disconnect switch to the off position.
Note:
Do not turn off the machine’s power
until the final shut down screen is
displayed.
 Operating Instructions
Hardware Insertion Machine Quality Assurance Package

Quality Assurance Package

Fastener Length Verification and Fastener
Presence Detection combined together to create
the Quality Assurance Package to help assure
the successful installation of hardware in
fabricated and stamped parts. The Quality
Assurance Package is used only with Haeger’s
top feeding shuttle style tooling for studs,
standoffs and nuts. It is most advantageous
when working with Haeger’s Single Touch
Handling solutions – the One Touch and the
Turret Insertion System. These systems allow
insertion of multiple types/sizes of hardware in ! CAUTION!
a single part handling and the new software To use the Fastener length and
helps ensure that the machine operator has
Fastener Detection options
inserted all of the fasteners in the part.
you must first set T.P.S for each
The Quality Assurance Package works in fastener.
conjunction with the machine’s built in counters
and part programs to help assure that all of the
fasteners have been inserted into the part prior
to an operator inadvertently moving on to the
next part. The system can be armed or
disarmed in the supervisory level of the control
unit.
The Fastener Length Verification system uses
the TPS set up procedure to determine the
length of studs and standoffs by looking at
when tooling contact is made. The
InsertionLogic software then stores the position
of the ram when tooling contact was made
using the CET value.
The Fastener Detection system uses the TPS set
up procedure to determine the position of the
ram when the Fastener Vacuum Switch is
activated as the vacuum anvil come in contact
with the fastener. The InsertionLogic software
then stores the position of the ram when the
fastener passes through the jaws using the CET
value.
The Quality Assurance Package is setup by
setting the T.P.S system. Please Refer to Setting
the T.P.S section in this manual.

4.35
Operating Instructions
Quality Assurance Package
Figure 4.55: If the fastener is too long
or too short by .040” ( 1.0 mm ) the
ram will retract and the Fastener
Length Error screen will appear on the
touch screen. Press the RESET button
on the touch screen to clear the error.
Remove the fastener and eject
Figure 4.56: If there is no fastener
present when the anvil passes through
the jaws, the ram will retract and the
No Fastener Error screen will appear
on the touch screen. Press the Reset
button on the touch screen to clear
the error.
4.36
Hardware Insertion Machine
Fastener Length Verification
The Fastener Length Verification system uses
the TPS set up procedure to determine stud or
standoff length by looking at when tooling
contact is made. The InsertionLogic software
then stores the position of the ram when tooling
contact was made using the CET value.
To activate the Fastener Length Verification for
each MAS/Tool station - Go to the program
screen and click on the More button. This
screen will have a check box for fastener length
and fastener detection. If checked the system is
on for that MAS/Tool station. See Page 4.24 for
more information on the More screen
If the fastener is too long or too short by
.040” ( 1.0 mm ) the ram will retract and a
RED warning page will appear on the touch
screen. Press the RESET button on the touch
screen to clear the error. Remove the
fastener and eject another fastener. (See
Figure 4.55)
Fastener Detection
The Fastener Detection system uses the TPS set
up procedure to determine the position of the
ram when the Fastener Vacuum Switch is
activated as the vacuum anvil comes in contact
with the fastener. The InsertionLogic software
then stores the position of the ram when the
fastener passes through the jaws using the CET
value.
The Fastener Detection system is activated by
turning on the Fastener vacuum and is
deactivated by turning off the Fastener Vacuum.
To turn on the Fastener Vacuum press the
Vacuum button on the touch screen, the button
will read ON. To turn off the Fastener Vacuum
press the button again and the button will now
read OFF.
If there is no fastener present when the
anvil passes through the jaws the ram will
retract and a RED warning page will appear
on the touch screen. Press the Reset button
on the touch screen to clear the error.
 Operating Instructions
Hardware Insertion Machine Quality Assurance Package

Fastener Detection System

Vacuum Switch
The Vacuum Switch displays the readout of the
vacuum and sends a signal to the PLC when the
set point has been reached and will allow the
ram to continue down. When the set point has
been reached the LED light will go out.
Figure 4.57
To set up the vacuum switch you must first
have all the tooling on and operational. (See
Figure 4.57) to get acquainted with the buttons
on the switch.
To set up the vacuum switch you must first find
out what the set point would be. Turn on the
vacuum by pressing the button on the touch
screen, then briefly step on the down pedal to
turn on the vacuum generator. You will then see
a reading on the vacuum switch ( Example 300 )
Now put a fastener onto the end of the vacuum
anvil and record the reading on the vacuum
switch ( Example 600 )
Figure 4.58
Now subtract 300 from 600 = 300. Divide 300
by 2 = 150, then minus 150 from 600, which
equals 450. This will be your set point.
Conversion Max vacuum - Minimum Vacuum
= X , X divided by 2 = Y, Max Vacuum - Y =
vacuum set point.
Once you have the set point number you will
now press the set button on the vacuum switch.
Do not hold the set button depressed or it
will change to other commands. A quick
press of the set button will bring up the
correct screen. A reading of n1 will show up on
the LCD screen. Use the up and down arrows to Figure 4.59
adjust the number to the desired set point. Now
you will press the set button again and a reading
of n2 will now be displayed. Use the up arrow Note:
to adjust this number to maximum vacuum Do not hold the set button
setting of 760. Now press the set button again depressed or it will change to
and the vacuum switch is now set up. other commands. A quick press of
the set button will bring up the
correct screen.

4.37
Operating Instructions
Tooling Protection System
! Warning!
NEVER place your hands or any
part of your body between the
Upper and Lower Tool.
! Warning!
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.
! Warning!
Never operate this machine while
wearing any metal objects such as
a watch, bracelets, or rings.
4.38
Hardware Insertion Machine
This system will always be activated when the
Vacuum system is activated. If you would like to
run manual tools with manual insertion you must
turn off the Vacuum by pressing the button on
the Touch Screen. The button will now read off
and the Fastener Detection system will be off.
You can also shut this system off by selecting
the more button on the bottom of the program
screen. There are two check boxes that if check
the system is enabled for that station. if
unchecked the system is disabled for that tool
station.
Tooling Protection System Description
The Tooling Protection System (TPS) is
designed to protect both the tooling and the
workpiece from damage. It works with
Haeger’s patented Safety System. When
properly set up, the TPS detects when the force
is about to be applied to insert the hardware. If
the position detected by the TPS is not correct,
the Upper Tool will retract without exerting the
insertion force. The TPS can also be turned Off
and Haeger’s patented Safety System will
remain fully operational. It is recommended,
however, that the TPS by used for all hardware
insertion operations.
The TPS is also fully adjustable for different
length tooling. It can be used with all Haeger
tooling setups including the J-Frame. It is
particularly effective when Automatic Tooling is
being used. If you inadvertently try to insert two
pieces of hardware at the same location in a
workpiece, the tooling or workpiece may be
damaged. The TPS will not allow the insertion
of a second piece of hardware, preventing
possible serious damage to the tooling and the
workpiece.
If you are unsure if there is hardware already in
the tooling, however, you must manually check
the tooling to be sure. This is particularly true if
you leave the machine, even for a brief period.
 Operating Instructions
Hardware Insertion Machine Tooling Protection System Setup

TPS Setup Procedure

Note:
This procedure assumes that you are
! Warning!
Never operate this machine while
thoroughly familiar with this machine’s
wearing any metal objects such as
controls as described in the first part of
a watch, bracelets, or rings.
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, call your Haeger Distributor.

Getting Started
! Warning!
NEVER place your hands or any
1. Follow the Setup Procedure for the Non- part of your body between the
Conductive Mode on page 4.30 in this Upper and Lower Tool.
section of the manual.
This includes having your supervisor use
their key to select the Non-Conductive Mode
of operation. You must also select and install
the proper tooling, set the required insertion
Force, and set an adequate Up Position.
2. Start the machine by pressing the On
Switch. The green light in the switch will
turn on and the motor will start.
If the machine does not start, twist the red
Off button clockwise, as indicated on the
button. If the machine is off, the button will
snap out and the machine can be started. Figure 4.60: Turn the TPS on.
3. Turn the TPS on by touching the TPS On/
Off button (See Figure 4.60)
4. Touch the Set TPS button on the
Touchscreen.

Setting the TPS for the Job

Note:
The InsertionLogic software greatly
simplifies the setup of the TPS. Follow
the steps and pictures displayed on the
Touch screen.

4.39
Operating Instructions
Tooling Protection System Setup
Figure 4.61: Follow the directions on
the screen. Turn to Non-conductive
mode.
Figure 4.62: Place the workpiece and
fastener in the machine and depress
the Down Footpedal.
Figure 4.63: If a TPS Error occurs, go
through the TPS setup again.
4.40
Hardware Insertion Machine
If at any time you want to stop the TPS
setup, touch the Cancel button on the
Touchscreen.
1. Switch to Non-conductive mode (Step 1 in
the software - (See Figure 4.61)
2. Position the workpiece and fastener.
Depress the Down Foot pedal until the
Upper Tool stops moving. (Step 2 in the
software) - (See Figure 4.62) Release the
Down Foot pedal.
3. Depress the Down Foot pedal a second time
(Step 3 in the software). Release the Foot
pedal when the screen changes.
4. Touch the Set TPS button on the
Touchscreen (Step 4 in the software).
5. Switch the machine back to Conductive
Mode (Step 5 in the software).
6. Carefully insert another piece of hardware
into the workpiece and check it. If the
insertion is acceptable, proceed with
production. If the insertion is not acceptable,
review this Setup Procedure.
The Setup Procedure is now complete.
If the production is going to be run in
Conductive Mode, it may start now.
If the production is going to be run in Non-
Conductive Mode, have your supervisor use
their key to select the Conductive Mode of
operation.
If a TPS error occurs, the software will alert
you with a red screen (See Figure 4.63) If you
receive a TPS error, go through the TPS setup
procedure again.
 Operating Instructions
Hardware Insertion Machine Loading Software
Loading Software Version 8
1. You must power down the computer (See
page 4.34) and then turn off main power to
the machine.
2. Insert Disk 1 into the floppy drive located on
the front of the machine.
3. Turn on the main power to the machine and
the Disk will self boot.
4. A message will appear on the touch screen,
asking you to turn off main power to the
machine and the remove Disk 1 and install Figure 4.64:
Disk 2. (See Figure 4.64)
5. After you have installed disk 2, turn the main
power back on to the machine. The Disk
will self boot, then a message will appear
asking you to remove Disk 2 and turn off
the main power to the machine, then restart
the machine after waiting 2 minutes. (See
Figure 4.65)
6. Upon restarting the machine the program
will erase the PLC and reload the program. It
will then bring up a screen that will prompt
you on how many lines have been saved to
the PLC, you will then click the OK button.
(See Figure 4.66)
Figure 4.65:

Figure 4.66: Click the OK button

4.41
Operating Instructions
Loading Software Hardware Insertion Machine

Updating Software Version 9

1. You must be logged in with an
Administration password.
2. Click on the Administration Button on the
Run screen
3. Press the Option button (See Figure
4.67)and then press Update IL on the bottom
of the screen. (See Figure 4.68)
Figure 4.67:
4. The on screen Prompt will appear
instructing you to insert IL Update Disk 1
Click the OK button after you have inserted
Disk 1 into the floppy drive on the front of
the machine.(See Figure 4.69)
5. The on screen Prompt will appear
instructing you to insert IL Update Disk 2
(See Figure 4.70)Click the OK button after
you have removed Disk 1 and inserted Disk
2 into the floppy drive on the front of the
machine.
Figure 4.68:
6. A prompt will appear letting you know the
Update has been completed. (See Figure
4.71)Remove Disk 2, then click the OK
button. You will then shut down the machine
by pressing the shutdown button in the
administration screen. Once the machine has
been shutdown you can then restart the
Figure 4.69: machine and the changes will take effect.

Figure 4.70:

Figure 4.71:

4.42