Safety System Upper Ram Perform safety system check procedures using Testing the Safety System

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1 Hardware Insertion Machine Maintenance Maintenance Schedule Maintenance Schedule 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.! Warning! D NT lubricate Upper Tool Holder with any lubricant other than a small amount of lithium grease (white). ther products may interfere with the Safety System. Component Area Maintenance Schedule Safety System Upper Ram Perform safety system check procedures using Testing the Safety System Daily Upper Tool Holder (See warning above) Upper Ram Small amount of lithium (white)* grease between upper tool holder & cylinder rod an ilters Electrical Cabinet Blow out filter with clean air. nce a month Every 3 months Hydraulic System ilter Lower Hardware Insertion Machine Motor Compartment Remove and replace cartridge nce a year Hydraulic luid Lower Hardware Insertion Machine Motor Compartment Change fluid. Use Mobil AW-32 or equivalent.** (22 gallons/88 liters.) nce every 2 years * Lithium Grease Each Haeger machine is shipped with a tube of Lubriplate 630-AA, produced by iske Brothers Refining Company. In Europe, iske Brothers is represented by Total Deutschland GmbH. ** Hydraulic luid Equivalent hydraulic fluids may be used. It is the machine owner s responsibility to obtain a fluid which is equivalent to Mobil AW

2 Troubleshooting Guide Hardware Insertion Machine Problem Source Solution Machine will not turn on. 1. ff Switch. 2. Disconnect Switch off. 3. No power to machine 4. Blown fuse. 5. verload relay tripped. 6. Circuit breaker tripped. 1. Rotate ff Switch clockwise. 2. Turn Disconnect Switch n. 3. Check for correct power supply. 4. Repair fault and replace fuse. 5. Reset overload relay. 6. Repair fault and reset. 1 fuse blows. 1. Possible PLC fault. 1. Contact factory. 3 fuse blows. 1. TPS fault. 1. Check TPS for short. 2. Possible PLC fault 2. Contact factory. 3. DC to DC converter 3. Contact factory. fault. 4 fuse blows. 1. Short in MAS. 1. Check MAS for short. 2. Line filter shorted. 2. Replace filter. 5 fuse blows. 1. ailed 4.8A power supply. 1. Replace power supply. 6 fuse blows. 1. Power supply and 1. Replace power supply. output failure. 8, 9 or 10 fuse blows. 1. R3 or R6 relay shorted. 1. Replace relay. 2. ailed safery relay board. 2. Replace board. 20 fuse blows. 1. ailed 4.8A power supply. 1. Replace power supply. 22 fuse blows. 1. Electrical cabinet fan shorted. 1. Replace fan. Machine starts but ram will not come down. 1. Pump direction of rotation is reversed. 2. Upper tool holder is sticking 3. PLC in PRG mode. 4. Ram shorted. (B and/or C inputs should be off) 5. ootpedal fault. 1. Check arrow on side of motor to verify correct rotation. Reverse L1 and L2 leads to change rotation if needed. 2. Remove and clean upper tool holder, lube with white grease. 3. Switch PLC to RUN mode. 4. Check cylinder for short to frame. 5. Check footswitch, pedal and cable. 6.2

3 Hardware Insertion Machine Troubleshooting Maintenance Guide Problem Source Solution When in the Conductive mode and Run mode the machine will not squeeze when the tool comes into contact with the material. When in the Conductive or Non-Conductive mode and Run mode the machine will build pressure but will not cycle up when pressure is reached. 1. Lower tooling is not tight on the frame. 2. Upper tool holder is not making contact with the cylinder shaft. 3. Tooling is not clean. 4. Nonconductive material. 5. Dirty material. 6. No 6VDC at Term Pressure switch contacts are closed. 8. TPS causing cylinder to retract. 1. The contacts in the pressure switch are not closing. 2. The Run/Setup switch is in the set up mode. 3. The contacts on the Run/Setup switch are stuck. 4. Defective dwell timer. 1. Check tooling and tighten if necessary. 2. Remove and clean. Replace continuity springs and guide pins. 3. Clean tooling with fine sandpaper. 4. Use the correct mode for Nonconductive material. 5. Clean material. 6. Check fuses 8, 9 and Adjust pressure switch or replace. 8. Check part and fastener for cause of TPS tripping. Check TPS setting. 1. The contacts may be adjusted. If not, then replace the switch. 2. Switch to the Run mode. 3. Replace the contact block on the switch. 4. Replace dwell timer. When in the Non- Conductive mode and Run mode, with TPS on, the machine will not build up pressure when the footswitch is depressed a second time. 1. TPS not set correctly. 1. Set TPS (See Instructions) 6.3

4 Electrical Schematic Hardware Insertion Machine SEE DRAWING INSDE CVER MANUAL BINDER 6.4

5 Hardware Insertion Machine Electrical Schematic SEE DRAWING INSDE CVER MANUAL BINDER 6.5

6 I/ List Hardware Insertion Machine INPUTS 0 Up Travel Input #1 1 Up Travel Input #2 2 Up Travel Input #3 3 Up Travel Input #4 4 Down oot Switch 5 Up oot Switch 6 Conductive(L) /Non Conductive(H) 7 Pressure Switch 8 Safety Switch Monitor 9 Safety Switch Redundancy Monitor A Tooling Protection Switch B Tooling Contact Monitor C Tooling Contact Redundancy Monitor D Run(L) /Setup(H) E Vacuum Generator n/ff N/C UTPUTS 0 N/C 1 N/C 2 N/C 3 N/C 4 N/C 5 N/C 6 N/C 7 N/C 8 Ram Down 9 Ram Up A Cycle MAS B Vacuum n/ff C N/C D Spare Ram Down E Bypass Valve N/C 6.6

7 Hardware Insertion Machine I/ Table Run Mode Conductive Mode Normal peration TPS & Vacuum ff Inputs A B C D E 8 utputs 9 A B C D E Idle Down Tool Contact Pressure Up * Idle Run Mode Non-Conductive Mode Normal peration TPS & Vacuum ff Idle Down Safety Switch Stop * * Release ootswitch * * Down #2 * * Pressure * * Up * Idle = n = Momentary lash * = May be either on or off 6.7

8 Hardware Insertion Machine 6.8

9 Hardware Insertion Machine Maintenance Problems Problems? Have you worked your way through the Troubleshooting Section in this manual? ou still haven t resolved the problem? Call your Haeger Distributor! Their telephone number is on the Basic Data Sheet in the Introduction Section of this manual. To save time, please be prepared to give your area Haeger Distributor the following information: 1. our name. 2. our company s name, location and telephone number. 3. The Model Number of your Haege machine. 4. The Serial Number of your Haeger machine. 5. A very detailed description of the problem. 6. What steps you have already taken to resolve your problem. 7. How the machine responded to each of the steps. 8. Visit ur web site at and check out our service web page. Cutomer Support/service. 6.9

10 Hardware Insertion Machine notes: 6.10