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2.7 Powerhead Setup
A group of Insight units synchronized together to perform a multiple bolt tightening task is called a Powerhead. If you
are arranging a series of Insight controllers together in this way, you must link them in a “daisy chain” fashion to create a
Powerhead Synchronization Bus. These can comprise up to 40 Insight controllers. You must also set each controller’s
two rotary address switches depending on its location in the chain.
1. On the rst Insight controller in the powerhead, the top rotary switch must be set to 0, while the bottom switch is
set to 1.
2. Connect a powerhead synchronization cable to the bottom
powerhead connector on the rst controller.
3. Connect the other end of the same cable to the top powerhead connector on the second unit in the chain.
4. On the second controller, set the top rotary switch on the second unit to 0, with the bottom switch set to 2.
5. Continue using this same pattern of cabling and rotary settings up to 40 units.
NOTE: The top rotary switch is set to 1 for units 10-19, 2 for units 20-29, 3 for units 30-39, and 4 for unit 40.
6. Set the terminal block for the rst and last units in the chain to 1 On and 2 O,.as shown below.
NOTE: All other units in the powerhead should be set to 1 O and 2 O.
2.8 Initial Startup
Before starting the Insight for the rst time, you must go through the following checklist and verify that all of the steps
have been completed. If in doubt about any aspect of this checklist, contact Ingersoll Rand.
The Insight controller enclosure is vertical, level, and securely mounted.
Ensure that the spindle is attached, and that the spindle cable connector is locked down.
If the Insight is equipped for attaching external devices (printers, computers, etc.), the proper devices have been
attached to the appropriate ports in the connector panel (located on the controller’s left side).
The AC power cord is plugged into a properly rated electrical circuit.
2.8.1 Startup Procedures
Once the above checklist is veried, you are ready to power-up the Insight Fastening System.
1. Turn the Insight Circuit Breaker Switch to O.
2. Ensure the unit is plugged into the appropriate power outlet: 120V, 16A or 230V, 8A; 50-60Hz.
3. Ensure the GFI (A) (Ground Fault Interrupt) is switched to the On (up) position.
• Switch the Insight Circuit Breaker (B) switch up to the On position. This switch sends power to the internal Mo-
tor Controller Electronics, the graphics display, the keypads, and to the spindle(s) or powerhead.
Figure 14 - GFI (A) and Circuit Breaker (B)
4. After approximately 130 seconds, the Run Main screen is displayed on the graphics display panel, indicating the
startup was successful and the Insight IC is ready to operate.
• If you need to turn the entire Insight system on or o use the Circuit Breaker Switch.
• After powering down, wait at least ve seconds before powering up again.