Fully Auto Vacuum Forming Machine - formechinc.com · the vacuum forming process such as: food products, all types of particles, powder, dust,

HD686/750

Installation, Operating and Service Manual

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Fully Auto Vacuum Forming Machine

Manual - Formech HD686/7502

Table Of Content

Safety 4

General arrangement 8

Specifications 9Foreword 9Specifications 9Features 9Noise emissions 10Machine storage 10Machine transportation, lifting and moving 10

Installation 11Electrical connection 11Pneumatic connection 11

Introduction 12

Operation - Main Menu Fuctions 13Powering up 13Main Screen Control 13User access Control 14Getting started 16Control POD Functions 16Operation Screen Safety Indicators 16

Operation - Manual Functions 17Control POD Manual Operation Screen 17Manual Setup - Heater 19Manual Cycle 20Manual Plastic Clamping 20Heating 20Auto-Level 20Pre-Stretch 20Plug-Assist 20Moulding 20Cooling & Release 20

Operation - Setup of Semi-Automatic Cycle 21

Operation - Setup Functions for Semi-Auto 23Semi-Automatic Timer and Pyrometer Settings 23Flip Sheet mode settings 23Pre-Stretch settings 23Plug assist settings 24Table settings 24Vacuum settings 24Cooling settings 24Cooling Pyrometer (optional) 25Release settings 25Cycle counter settings 25Save program 25


Table Of Content

Pyrometer Option 27Heater Security Mode 27User PIN Access Control (Option) 28Fixed Table mode (Option) 29Interlocks 29RESET 29Fixed Table Mode Access 29

Machine Adjustments and Settings 30Speed Adjusment 30Clamp Frame rear spring adjustment 30Cooling Fan Adjustment 30Plug assist mechanical stop (Option) 30Clamp insert reducing bars 30Fixing mould tools 31Table Height Adjust (Lower Limit) 31Table Height Adjust (Upper Limit) 32Pyrometer Air Pressure (Option) 32Reel Feed (Option) 32Mist (Option) 33

Fault Diagnostics / Maintenance 34Electrical 34Software interlocks 34Heater 35Replacement of heating elements - Top heater 35Auto-Level Sensing 35Vacuum 36Pneumatics 37General lubrication 37Clamp & Table Seals 37Replace a damaged or worn seal 38Cleaning 38Service Support 38

Periodic Maintenance 39

Warranty 40Seals 40Heating Elements 40Vacuum System 40

Electrical Schematics (Index) 41

Parts Listing 76

EC Certificate 80


Safety

Thank you for choosing Formech.Please read and follow the below safety instructions before attempting to install

or operate your machine.

Special attention should be paid to sections dealing with safety.

It is impossible to cover all aspects of thermoforming within the scope of this manual, we are therefore available to offer advice on special problems regarding thermoforming techniques, tooling and materials.

1) The electrical supply to the machine must be of adequate capacity. Wiring must be to local regulations and carried out by a suitably qualifi ed technician. THIS MACHINE MUST BE EARTHED IN ACCORDANCE WITH LOCAL REGULATIONS.

2) Ensure that the pneumatic air supply is regulated to 5 BAR or less and is properly fi ltered & lubricated using a good quality airline oil. A competent person must make compressed air connections.

3) Do not operate the machine until you have been trained and are fully conversant with it. Read and understand all of this User Manual. Users of this machine should complete regular competence tests.

4) Never remove any panels unless both the electrical and pneumatic supplies have been isolated. Never remove any warning labels from the machine. It is important to understand that high pressures may be present within parts of the pneumatic system even after the supply has been isolated. Special care must be taken if any parts have become jammed to ensure that all pressure is removed before attempting a repair.

5) Daily repetitive use of this or any other machine may lead to a) fatigue and loss of concentration. b) possible strains. Operators should be trained in the use of correct lifting techniques in order to minimise these effects.

6) When servicing the machine care must be taken to prop any heavy moving parts. This refers particularly to the mould table, clamping frame and counter balance weights. Always restrict movement of these parts before entering any part of the machine to prevent possible injury.

7) Always let the machine cool down before attempting to work on it. Some parts of the heater and heat shield become extremely hot during operation.

8) Only use the machine for vacuum forming and blow moulding of plastic. It is not intended for any other purpose.

9) Ensure that the area you are working in is properly ventilated and that you are aware of the potential hazards from the plastics you are forming.

10) Ensure that the area surrounding the machine is clean and frequently cleared of fi nished product and any waste.

11) This machine is fi tted with an Oil rotary vacuum pump. Ensure the vacuum fi lter mounted on the pump is periodically cleaned of dust and particulate. Periodically check the oil level and ensure it is maintained at the level shown in the inspection window.


Safety

It is vital that any person using this machine and the person(s) responsible for the health & safety is made fully aware of the potential hazards that could arise from the use and misuse.

These can be broadly categorised as: -

1. Electric Shock. This machine uses Voltages up to 415V.NEVER ATTEMPT ANY REPAIR UNLESS THE ELECTRICAL SUPPLY HAS BEEN LOCKED IN THE OFF POSITION. ONLY SWITCH ON WHEN ALL COVERS & GUARDS HAVE BEEN REPLACED.ONLY A QUALIFIED ELECTRICAL TECHNICIAN MAY WORK ON ANY PARTS CARRYING MAINS VOLTAGE AND SHOULD BE RESPONSIBLE FOR ENSURING THAT THE MACHINE IS IN A SAFE CONDITION BEFORE ALLOWING SERVICES TO BE RESTORED.

2. Burning. Parts of this machine reach temperatures in excess of 300°C over large areas.WAIT UNTIL THE MACHINE HAS COOLED DOWN BEFORE SERVICE WORK COMMENCES.SPECIAL PRECAUTIONS MUST BE TAKEN TO ENSURE THAT ONLY THE MACHINE OPERATOR IS IN THE OPERATING AREA DURING USE.USE PERSONAL PROTECTIVE EQUIPMENT SUCH AS GLOVES WHEN TESTING THE HEATED PLASTIC, HANDLING HOT VACUUM FORMED PARTS, MANUALLY ASSISTING THE FORMING PROCESSS AND TOUCHING HOT SURFACES.INFRARED RADIATION IS EMITTED BY THE QUARTZ HEATERS, ENSURE THAT ANY EXPOSURE TO THIS TYPE OF RADIATION IS SHORT OR COMPLETELY AVOIDED.

3. Injury from Compressed Air. Pressures up to 80 PSI will be present in large volumes on this machine. BE EXTRA CAUTIOUS WHEN DEALING WITH COMPRESSED AIR EVEN AFTER THE MAIN SUPPLY HAS BEEN SHUT OFF DANGEROUS RESIDUAL PRESSURE MAY STILL BE PRESENT WITHIN THE SYSTEM.

4. Toxic Fume Inhalation. When large sheets of plastic are heated fumes will be given off.ENSURE THAT THE MACHINE IS POSITIONED IN AN ADEQUATELY VENTILATED PLACE. ASSESS THE RISKS OF THE MATERIALS TO BE FORMED PRIOR TO USE.

5. Injury from Moving Parts. Where pneumatics components are used to power moving parts there is a risk of personal injury. NEVER REMOVE ANY PANEL OR ATTEMPT ANY REPAIR UNLESS THE COMPRESSED AIR SUPPLY AND THE ELECTRIC SUPPLY HAS BEEN DISCONNECTED. BE EXTRA CAUTIOUS WHEN DEALING WITH COMPRESSED AIR. EVEN AFTER MAIN SUPPLY HAS BEEN SHUT OFF DANGEROUS RESIDUAL PRESSURE MAY STILL BE PRESENT WITHIN THE SYSTEM. NEVER ATTEMPT TO OVERIDE ANY CONTROL SYSTEM INTERLOCK OR SAFETY RELATED CONTROL SYSTEM SUCH AS THE EMERGENCY STOP SYSTEM.

HEALTH & SAFETY - Hazards specifi c to this machine.



Safety

6. Injury from Trapping.There is a risk of trapping fi ngers and hands when loading mould tools. Ensure appropriate care is taken to prevent trapping and use suitable personal protection. Care is required when operating the clamping frame to ensure that fi ngers or hands are not trapped.Keep hands clear of the heater rails when pulling the heater forwards.

7. Lifting, Reaching and Stretching. TAKE CARE WITH LIFTING REACHING AND STRETCHING WHEN PERFORMING THE FOLLOWING ACTIVITIES:- The loading of materials and unloading of plastic formings.- The fi tting and loading of mould tools.- Loading and fi tting of reducing plates and frames.- Fitting and adjustment of Fans. - Replacement and maintenance of top frame and table seals.ENSURE THAT LOCAL LIFTING AND HANDLING PROCEDURES ARE APPLIED AND MONITORED BY A PERSON RESPONSIBLE FOR HEALTH AND SAFETY.

8. Fire. The sheet auto-levelling system allows the level of heated plastic to be kept constant. There is a risk that failure of the level sensors due to misuse of heaters OR the setting of the compressed air supply to a level that exceeds the operating pressure of pneumatics valve and the machine specifi cation may cause the plastic to be blown into the heaters and to be ignited. Periodically monitor and check the condition of the infrared beam sensors.ENSURE THE COMPRESSED AIR SUPPLY IS SET TO THE RECOMMENDED LEVEL AND ONLY USE THE HEATER FOR THE HEATING OF VACUUM FORMING PLASTIC MATERIALS.RISK OF FIRE AS A RESULT OF HEAT AND PLASTICS PRESENTS AN EMERGENCY SITUATION. ENSURE FIRE SAFETY TRAINING IS PERFORMED & CONTROLLED.IT IS ESSENTIAL TO HAVE FIREFIGHTING EQUIPMENT AVAILABLE AT OR NEAR THE MACHINE. USE DRY POWDER (BLUE) OR CARBON DIOXIDE (BLACK) FIRE EXTINGUISHERS.

9. Airborne Particles. Particles present in the working area may become airborne during the use of the fan cooling system, when using an airline to blow onto plastics and when the release function is operated without tooling fi tted.ENSURE THAT THE DUST, PARTICLES AND DEBRIS IN THE WORKING AREA ARE KEPT TO A MINIMUM. ENSURE THAT SUITABLE EYE PROTECTION IS WORN.

10. Working at Height.When installing the fan cooling system or when making adjustments or performing servicing at the top of the machine, it is necessary to work at an appropriate height.Ensure that adequate safety precautions are taken to prevent falling from height and that suitable, stable and secure equipment is used to support your weight when working at height. Ensure that you DO NOT work on your own when working at height.ENSURE THAT LOCAL LIFTING HANDLING AND HIGH LEVEL WORKING PROCEDURES ARE APPLIED AND MONITORED BY A PERSON RESPONSIBLE FOR HEALTH AND SAFETY.



Safety

11. Prohibited Uses

DO NOT USE THIS MACHINE FOR ANY PURPOSES OTHER THAN THE VACUUM FORMING AND BLOW MOULDING OF PLASTICS SHEET.

DO NOT USE THE HEATER TO APPLY HEAT TO ANY MATERIAL OTHER THAN PLASTIC SHEET AS PART OF THE VACUUM FORMING PROCESS SUCH AS: FOOD PRODUCTS, ALL TYPES OF PARTICLES, POWDER, DUST, ALL TYPES OF LIQUID, WOOD, PAPER, METALS AND ANY FORMS OF COMBUSTABLE MATERIALS.

DO NOT USE THE TABLE MECHANISM TO CLAMP, COMPRESS, FOLD OR APPLY FORCE TO ANY ITEM UNDER ANY CIRCUMSTANCES.

DO NOT USE THE PLUG ASSIST OR CLAMPING FRAME TO CLAMP COMPRESS, FOLD OR APPLY FORCE TO ANY ITEM OTHER THAN THE CLAMPING OF SHEET PLASTICS AS PART OF THE VACUUM FORMING PROCESS.

DO NOT USE THE RELEASE TABLE AIR FUNCTION TO APPLY PRESSURE FOR ANY OTHER MEANS OTHER THAN TO RELEASE THE MOULDING FROM A FITTED MOULD TOOL.

DO NOT USE THE TABLE VACUUM PORT TO SUPPLY VACUUM FOR ANY OTHER MEANS OTHER THAN TO APPLY VACUUM UNDER A MOULD TOOL AS PART OF THE VACUUM FORMING PROCESS

DO NOT USE THE MACHINE TO STACK OR LEAN ITEMS AGINST THE SIDES.

DO NOT USE OR MODIFY THE ELECTRICAL POWER IN THE CONTROL PANEL TO SUPPLY ANY OTHER DEVICE OR TO APPLY MODIFICATIONS TO THE MACHINE OR ITS FUNCTIONS.

THIS IS NOT AN EXHAUSTIVE LIST OF THE POSSIBLE MISSUSE OF THIS MACHINERY. THIS LIST IS WHAT IS CONSIDERED TO BE FORESEEABLE MISSUSE.

THE USE OF THIS MACHINE MUST BE ASSESSED, MONITORED AND CONTROLLED BY THE PERSON RESPONSIBLE FOR THE HEALTH AND SAFTEY IN THE ORGANISATION THAT OWNS AND OPERATES THIS MACHINE.


General arrangement

Machine footprint

1165

2251 2639

1947

1190

1553


Specifications

Foreword Please read this manual thoroughly before attempting to install or use this machine. Special attention should be paid to sections dealing with safety.It is impossible to cover all aspects of thermoforming within the scope of this manual, we are therefore available to offer advice on special problems regarding thermoforming techniques, tooling and materials.

Specifications

HD686Forming area: 647mm x 622mm. Depth of draw: 350mm Sheet Size: Nominal 686mm x 660mmMaterial thickness 0.25mm min. 6.0mm maxElectricalPower - 11kW - Supply 380-415V, 5 wire, 3 phase + Neutral + earth, 50Hz, 32A (Europe)Power - 11kW - Supply 208-220V, 4 wire, 3 phase + Earth, 60Hz, 40A (North America)Air Supply: Approx. 10 cu. ft / min @ 80 psi (approx. 300l / min @ 5 bar.)Width: 1553mm Depth: 2639mm Height: 2480mm Height with plug assist: 2600mm Weight: 750Kg

HD750Forming area: 700mm x 500mm. Depth of draw: 350mm Sheet Size: Nominal 750mm x 540mmMaterial thickness 0.25mm min. 6.0mm maxElectricalPower - 11kW - Supply 380-415V, 5 wire, 3 phase + Neutral + earth, 50Hz, 32A (Europe)Power - 11kW - Supply 208-220V, 4 wire, 3 phase + Earth, 60Hz, 40A (North America)Air Supply: Approx. 10 cu. ft / min @ 80 psi (approx. 300l / min @ 5 bar.)Width: 1553mm Depth: 2639mm Height: 2480mm Height with plug assist: 2600mm Weight: 750Kg

Features• PLC with 10” Touch sensitive HMI • Quartz single heating with proportional heat level control, adjustable in 1% Increments and power standby feature• Heater profile power trim features• Flip sheet mode for thicker materials• Heating ‘Pause’ & ‘Advance’ feature• 40 Program memory capabilities• Real time user timing adjustment / setting by touch screen• PLC / HMI remote access.• Cycle counter and cycle time monitoring


Specifications

Features (continuation)• Automatic sheet levelling• Pre-stretch and mould release• 115Ltr vacuum tank • Air fan cooling• Pneumatically powered mould/ table lift with table height adjustment• Pneumatic clamping hinged at rear• Real time user timing adjustment / setting by touch screen• Vacuum and pressure gauge indication• Vacuum flow control• 2 channels monitoring emergency stop function• 2 channels monitoring safety guarding• Air flow regulation control - Table, plug, pre-stretch, release.

Noise emissionsNoise emissions on the Formech HD686/750 are less than 70dB(A).

Machine storageThe Formech HD86/750 must be stored in a dry environment. If the machine is not used for a long period of time, run the pump periodically (once a month).

Machine transportation, lifting and movingBefore lifting, remove all separate assemblies and leave the heater fixed in its position until positioning at its operating site. Remove packaging where it assists with lifting and moving.The centre of gravity is at the machine centre.

Ensure lifting forks pass through the main cabinet.

Ensure that local lifting and handling procedures are applied and monitored by a person responsible for health and safety.


Installation

The machine should be sited on a level concrete fl oor. Dusty or draughty areas will compromise machine performance but it is important to allow enough space (750mm) around the machine to allow access into the various panels and to ensure a good airfl ow to prevent overheating. During all of the following installation ensure that the power supply is properly isolated.

Electrical connectionAn electric supply of correct voltage, current & frequency is required. An isolating switch with facility to be locked in 'OFF' position and capable of handling full current should be wall mounted, within easy reach of the operator.

380-415V Three phase supplyThe major current consuming devices within this machine are 230V single phase. However, in order to balance the load to electricity generator's requirements, each phase of a standard three-phase supply should be connected to the L1 L2 & L3 of the machine. A neutral wire of full load capacity is required in this case.

208-230V Three phase supplyA three-phase supply should be connected to the L1 L2 &L3 of the machine. A neutral is not required. Cabling should be rated at 40A per phase.

THIS MACHINE MUST BE EARTHED

Pneumatic connection If the air supply is insuffi cient the performance of the machine will be compromised. The connection to the machine should be via a lockable shut off valve. Ensure that the pneumatic air supply is regulated to 5 BAR or less and is properly fi ltered & lubricated using good quality airline oil. A competent person must make compressed air connections.If fl exible hoses are used it is strongly advised that they are of Nylon, canvas or wire reinforced rubber and suitably rated for pressure and temperature. The connection hose size should be 12mm diameter or 1/2” BSP.

Maximum airline pressure must not exceed 5 BAR or 80 PSI.

If the air supply is insuffi cient the performance of the machine will be compromised.

If t The connection to the machine should be via a lockable shut off valve.

The HD686/750 must be installed and commissioned by a Formech qualifi ed technician.

It is essential to read and fully understand all the information in this manual relating to safety and the Safety Hazards specifi c to this machine before installing and operating.

Operating procedures for this machine must be assessed, monitored and controlled by the person responsible for health and safety.


Introduction

The HD686 / HD750 is a large vacuum forming machine for sheet feed production suitable for forming a wide variety of plastic materials. It has been designed with operating simplicity high on the list of priorities.

Operators who have previously used vacuum forming machines will quickly become familiar with the user-friendly controller programming.

Whether required for long or short production batches or for prototyping or sampling the HD686 / HD750 adapts quickly to most needs.

The Formech HD686 / HD750 uses the reliable and robust Wago PLC with Weintek 10” Touch screen user interface.

Formech have produced high quality functional graphic software to give an easy to use, fl exible and versatile Thermoforming machine for all forms of industrial and commercial use.

The HD686 / HD750 Software provides for both manual and semi-automatic functionality of the vacuum forming process.

The following section explains the HD686 / HD750 control functions:

1. Main menu functions.2. Manual Operation, Heater Settings and the Vacuum Forming Process.3. Set up and use of the Automatic & Semi-Automatic Operation.


Operation - Main Menu Fuctions

Powering upEnsure the Emergency stop button is latched out.Turn ON the mains isolator at the control panel at the rear of the machine. The main menu will be shown as below.

Main screenThe Main Menu shows the options. Button descriptions are below.On machine start up default settings are loaded for the heater zones to allow for manual operation.Familiarise yourself with the button icons.

HeaterPress this button to activate the heater. The heater must be ON to use the machine. The heater may be switched off during machine idle periods or tooling set up.

PumpPress this to enable the pump. The vacuum pump can be switched off when not required e.g. during machine or tooling set up.

Automatic ModeOperate the machine using the automatic or semi-automatic cycle by selecting a stored program from the memory.

Manual ModeOperate the machine with each action of the machine being activated by the operator.

Access ControlOptional feature to control the user access to the machine using a numerical pass code. (Option)

LanguageSelect the required language.

HELP Function This icon can be pressed at any time for an explanation of the icons.

Main Screen Control

?


Operation – Main Menu Functions

User access ControlPress the user access icon. The following screen will open:Press the user access icon. The following screen will open:

Enter the desired PIN level using the pop up keypad.Enter the correct 4 digit PIN code for the selected level using the pop-up keypad.Press the Return button to operate the machine at that level.Return to this screen to LOGOUT when required.

The following functions may be used with the corresponding PIN level. PIN codes may be changed using user level 4.

DESCRIPTION ACCESS LEVELUSER LEVEL 0 1 2 3 4

DEFAULT CODE / 4321 4322 4323 4324

USER LEVEL DESCRIPTION MACHINE LOCK RUN & VIEW ONLY

RUN, ADJUST BUT NO SAVE RUN & SET CHANGE PIN

LEVEL ONLY

HEATERS ON / OFF YES YES YES YES YES

PUMP ON / OFF YES YES YES YES YES

LANGUAGE CHANGE YES NO YES YES YES

PIN ACCESS NO YES 1 YES 1-2 YES 1-3 YES 1-4

PIN CHANGE NO NO NO NO YES

MANUAL MODE NO YES YES YES

AUTO / SEMI-AUTO MODE NO YES YES YES

START NO YES YES YES

STOP NO YES YES YES

RESET NO YES YES YES

PAUSE NO NO YES YES

JUMP NO NO YES YES

AUTO-LEVEL CHANGE STATE NO NO YES YES

HEATER SECURITY CHANGE STATE NO NO YES YES

TIMER / PYROMETER MODE NO NO YES YES

HEATING PYROMETER TARGET VALUE NO NO YES YES

COOLING PYROMETER TARGET VALUE NO NO YES YES

HEATER SETTING SCREEN TH* 686 / 750 NO VIEW YES YES

HEATER SETTINGS SCREEN BH* 686 / 750 NO VIEW YES YES

HEATER POWER VALUE TH* BH 686 / 750 NO NO YES YES

HEATER POWER SET TH* 16 ZONE BH* 10 ZONE 686 / 750 NO NO YES YES

HEATER STANDBY VALUE TH* BH* 686 / 750 NO NO YES YES

s the Return button to operate the


DESCRIPTION ACCESS LEVELUSER LEVEL 0 1 2 3 4

DEFAULT CODE / 4321 4322 4323 4324

USER LEVEL DESCRIPTION MACHINE LOCK RUN & VIEW ONLY

RUN, ADJUST BUT NO SAVE RUN & SET CHANGE PIN

LEVEL ONLY

HEATER TRIM % VALUE TH* BH* 686 / 750 NO NO YES YES

HEATER TIMER SCREEN VALUES - FLIP SHEET ON/OFF NO NO YES YES

HEATER TIMER SCREEN VALUES - HEAT TIMES (3) NO NO YES YES

PRE-STRETCH SETTING SCREEN NO VIEW YES YES

PRE-STRETCH SETTING SCREEN TIME VALUE, ON/OFF NO NO YES YES

PLUG SETTINGS SCREEN NO VIEW YES YES

PLUG SETTINGS SCREEN TIMES, ON / OFF NO NO YES YES

TABLE SEETTINGS SCREEN NO VIEW YES YES

TABLE SETTINGS SCREEN TIMES, FIXED TABLE ON/OFF NO NO YES YES

VACUUM SETTING SCREEN NO VIEW YES YES

VACUUM SETTINGS SCREEN TIMES NO NO YES YES

COOLING SETTINGS SCREEN NO VIEW YES YES

COOLING FAN & MIST ON/OFF, TIME & TARGET TEMP VALUES NO NO YES YES

RELEASE SETTINGS SCREEN NO VIEW YES YES

RELEASE SETTINGS SCREEN TIME VALUES NO NO YES YES

HELP SCREENS NO YES YES YES

PROGRAM SELECT MODE NO NO YES YES

SAVE MODE NO NO NO YES

CYCLE COUNTER MODE NO VIEW YES YES

CYCLE COUNTER ADJUST VALUES NO NO YES YES

TH*: Top HeaterBT* : Bottom Heater

Refer to the section relating to ‘Setup functions for Semi Auto - User PIN access control’ for user PIN changes – level 4.

Operation – Main Menu Functions

User access Control - Continuation


Operation - Main Menu Functions

Getting startedOn the main menu screen Turn the Heater ON Ensure the Pump is ON Select Manual Mode

Control POD Functions The following section describes the manual controls of the HD686/750. Operate all of these controls independently to ensure you are fully familiar with how the machine operates and how each action behaves.

Vacuum & Pressure Gauges

Touch Screen

Emergency Stop

Emergency StopThis momentary action latching button cuts the power to all outputs when pressed. The indi-cator shown will be displayed on the touch screen if pressed. The button will need to be ma-nually reset for normal operations to continue. Only use this button in emergency situations.

AIRThis indicator will show if the air supply to the machine is lost. The heaters will shut off until air is restored. (Heating pyrometer option only)

GuardWhen the Light guard is broken power is cut to all critical outputs. The Blue button on the control POD will illuminate. Press this button to reset the Light guard. The indicator shown will be displayed on the touch screen when the light guard is broken.

Operation Screen Safety Indicators

AIR

Guard Reset


Operation - Manual Functions

Press the Manual Button on the main menu screen – The Manual Operation Screen will open as shown.The meaning and operation of the buttons on this screen are shown below.Following is a full description of the vacuum forming process.

Control POD Manual Operation Screen

The screen icons are designed to be followed round in a clockwise direction, starting with the clamp (top left) and ending with the release button.

Auto-levelThis button enables the auto-level feature. If the plastic is sagging and not being heated evenly then the auto-level feature may be used to keep the plastic level while the heater is forward and until the heater is fully back.ClampAllows movement of the material clamp UP & DOWN.

Heater Zone SettingsThese buttons allows direct and real-time adjustment of the heater zone settings.

Heater DriveThese buttons control the movement of the heater. There are separate buttons for the top heater and the bottom heater. The direction of heater movement is reversed each time the button is pressed. In manual mode the timer counts up. Pre-StretchPress the Pre-stretch button to infl ate the plastic before moulding.



Plug AssistPress the plug UP & DOWN arrows on the button descend and retract the plug plate.

Mould TablePress the Table UP & DOWN arrows on the button to raise and lower the table.

VacuumThe vacuum icon is used to apply vacuum to the table. The vacuum tank is continually evacuated by the vacuum pump. In manual mode the timer counts up. This button latches ON when pressed. Press again to turn OFF.FansPressing the fan icon will turn the cooling fans ON. Press again to turn OFF. In manual mode the timer counts up.ReleaseThe release icon is used to blow compressed air between the mould and the fi nished moulding. This is a momentary HOLD TO RUN button.

Flip Sheet ModeThis is a feature where thicker materials may be fl ipped on a single heater machine. Two heat times are set. This button shows Green when this mode is enabled. Semi-automatic mode only.Heater Security ModeThis feature will over-ride the Heater / Table interlock to allow the table to be raised when the heater is still in the forward position. This feature is only to be used with very shallow moulds. Mould height must be verifi ed to prevent collision with heater. Heater Quartz Standby FeatureWhen quartz heaters are installed the standby setting allows the heater to idle at a lower power setting when in the rear position.



Manual Setup - HeaterSelect the Manual icon on the main screen. Press the heater zone settings buttonsThe heaters are controlled by the PLC system to vary the output of individual zones as displayed on the touch screen. Allow 10 - 15 minutes for the heaters to reach operating temperature before attempting to run any mouldings. To change the heating zone settings press the heat zones settings button on the manual operation screen.

HD686

There are 16 heating zones on the HD686.The heater must be set to ‘ON’ to operate.The set power % is shown on each zone.

The power setting box shows the power level that is to be used to set each zone power. Press on this value to change the power level to be used and press on each of the zones that require this setting. The value will transfer to the zone. Change the power level to set other zones as required.

The power setting box shows the

The trim function will adjust all zones UP & DOWN by pressing the + / - buttons.The Standby setting is used to set the idle power setting for the quartz option. The heater will run at this reduced % when in the rear position. The fl ip sheet button will show green when the fl ip sheet mode is ON.The Heater timer and fl ip sheet settings apply to the semi-automatic mode.

HD750

There are 16 heating zones on the HD750.All settings functions operate the same as the HD686 above. The HD750 heater layout is shown.



Manual Cycle Once the mould is correctly located on the mould table, a manual cycle may be attempted.

Manual Plastic ClampingPlace the plastic over the forming area and ensure the material covers the top frame seal completely. Once the clamp frame is over the plastic correctly reset the guard. Press the Clamp button.

HeatingPress the heater icon and the heater will be driven forward over the plastic and stop automatically when the front limit switch is triggered. The heating of the plastic sheet may be checked by pressing the heater icon to send the heaters to the rear momentarily.

Auto-LevelIf the plastic is sagging and not being heated evenly then switch the auto-level feature on, in the centre of the touch screen. If the plastic sheet drops and breaks the sensor beam, short bursts of air will be blown in to the chamber under the heated plastic ensuring the plastic remains level.

Pre-StretchIf the moulding is quite high it may be necessary to pre-stretch the plastic before moulding takes place. To do this press the pre-stretch button when the heater is in the back position.

Plug-AssistPlug assist function timings require accuracy and hence it may be impractical to apply to moulding in manual mode. Manual control may be used during set up to verify plug tool positioning.

MouldingSend the heater to the back position by pressing the heater button when the plastic is at the correct temperature for moulding. When back, raise the mould into the plastic using the UP arrow on the table button. Press the vacuum button to apply vacuum to the table.

Cooling & ReleaseAt the appropriate time, the fans may be turned on to start the plastic cooling process. Once the plastic has cooled suffi ciently, the release icon may be pressed to blow the moulding off of the mould. The moulding is now complete and the table may be lowered and the clamp frame raised.


Operation - Setup of Semi-Automatic Cycle

On the main menu press the semi-auto button The semi-automatic screen shows all the stages and functions of the cycle. The stages follow the grey oval beginning with the clamp. Parameter / timing settings for each stage are performed by pressing the corresponding button. Changes are made immediately. When the semi-auto screen is opened, the parameter settings for the last program used will show.

The purpose of the additional buttons are shown below:

On the main menu press the semi-auto button

RESETPress this button to return all assemblies to the home position. The START button will show.

STARTThis button will start the auto cycle. When pressed the STOP button will show.

STOPThis button will perform a controlled stop. A small rectangle will show when activated. The machine will stop at the end of the cycle.

Semi-automatic screen & buttons


Operation - Setup of Semi-Automatic Cycle

Timed Heater CycleWhen this button shows, the auto cycle is set for the timed cycle and the heaters will operate for the times set.Press this toggle button to set to the pyrometer heat cycle.Pyrometer timed cycleWhen this button shows the auto cycle is set for the pyrometer control and the heaters will operate from the target temperature set. The temperature of the materials shown above the button and the target temperature is shown below the button.Press this toggle button to set to the timed heat cycle.PROGRAM SelectPress this button to load a different program. The load program screen is opened.

SAVE ProgramPress this button to save the changes made to the current program. The save screen shown all the parameters for fi nal check.

CYCLE CounterThis feature will count the quantity of automatic cycles. Press this to set the batch counter and reset the counter. The number shown in the oval shows the batch counter setting. The number shown at the top shows the actual count quantity.BACK or RETURNThis button will return to the main menu.

PAUSEThis button is a manual over-ride to pause the heating stage timer. It is essential to monitor this manual intervention to prevent material overheating.

JUMP / AdvanceThis button is a manual over-ride to end the heating stage timer before time-out or to end the heating stage after Pause’ is applied.


Operation - Setup Functions for Semi-Auto

The Semi-Automatic mode operates for single cycle only.The cycle timing parameters are set ‘real-time’ by pressing on the corresponding function buttons on the screen.Operation can be set to work from timer or the pyrometer (if option is fi tted).The heater timings may be paused or advanced manually.

Semi-Automatic Timer and Pyrometer SettingsSet the top heater time by pressing the heater button on the auto screen. Press number heater timer button. Adjust the times using the pop-up keypad. For standard operation use Heat time 1. The Pyrometer target value is set on the operation screen by pressing the value shown under the pyrometer button and using the pop up keypad.

Flip Sheet mode settingsSet the fl ip sheet mode ON if required.Set both times by pressing on the time values of Heat time 1 & Heat time 2 using the pop up keypad.If the fl ip sheet mode is set OFF then use only heat time 1.The delay time is only required for the double heater option - for single heater options set this value to zero.

Pre-Stretch settingsSet the Pre-stretch parameters by pressing the pre-stretch button on the auto screen.Enable the Pre-stretch by setting the toggle button to ‘ON’.Set the Pre-stretch time and the delay time (if required) by pressing on the time value and using the pop up keypad.



Plug assist settingsSet the Plug Assist parameters by pressing the Plug button on the auto screen.There are 2 plug stages: 1. Mould plug & 2. Release plugEnable the function by setting the toggle buttons to ‘ON’ or ‘OFF’ as required.Set the Plug times and the delay times (if required) by pressing on the time value and using the pop up keypad.

Table settingsSet the Table parameters by pressing the Table button on the auto screen.The Table DOWN command is triggered at the end of the Vacuum time and hence when Mould Release is required the TABLE DOWN DELAY TIME will need to be set to the same value as the RELEASE time.Set the times by pressing on the time value and using the pop up keypad.

Cooling settingsThe cooling setting page is accessed by pressing the FAN button on the operation screen and allows editing of the cooling fan, spray mist and cooling pyrometer settings.Each feature may be turned ON or OFF. Enable each feature as required if the options are fi tted.Set the FAN or MIST time and the delay time by pressing on the time value and using the pop up keypad.Set The cooling pyrometer target value. The actual cooling temp is shown on the LHS.

Vacuum settingsSet the Vacuum parameters by pressing the Vacuum button on the Semi-auto operation screen.Set the Vacuum time and delay times (if required) by pressing on the time value and using the pop up keypad.



Cooling Pyrometer (optional)The cooling pyrometer feature allows monitoring of the vacuum forming temperature after moulding. The set target temperature must be set to a value that achieves adequate product temperature. This temperature will override the vacuum time and the vacuum stage will fi nish when this temperature is reached. The actual temperature of the product is shown on the vacuum button when this feature is enabled. The target temperature is shown below the Fan Button.

Release settingsSet the Release parameters by pressing the Release button on the auto screen.Set the Release time and delay time (if required) by pressing on the time value and using the pop up keypad.The Release Air is triggered at the end of the Vacuum time and may be set to the same as the Table DOWN Delay time so the mould tool descends after release. The release time may be set longer than the table DOWN delay if required.

Cycle counter settingsSet the Cycle Counter parameters by pressing the cycle count button.The RESET button will reset the count to zero.Set the batch target value using the pop up keypad.The last cycle time and the average cycle time is shown on this screen.

Save programPress the PROGRAM button to open and load a saved program.

Select the required program number to load in auto / semi-auto mode.



Press the SAVE button to save programs.

To save an existing program, select the required program and press the SAVE button. To save as another program select another program number and press the SAVE button.The Save Parameters screen will open showing the parameters set. This allows fi nal review and adjustment. Press the SAVE button to complete.



When the pyrometer button shows the heater cycle will be completed when the material reaches the target temperature. The value is shown below the button. The Actual temperature is shown above the button

When the timer button shows the heat cycle will operate from the time shown on the heater buttons. The actual pyrometer temperature is shown above the button.

Pyrometer Option When in Semi-Auto, the heat cycle may operate from the heater timers or the pyrometer.

Semi-automatic Operation

Give consideration to the timings set for the semi-auto sequence. It may be necessary to run the product in the manual mode fi rst to establish the required time for settings.

The times for each stage of the process will affect the product produced.The time settings can be adjusted while the machine is operating. Adjust the set times for optimum

performance and monitor the output.Simply press the button of a function, make the setting changes and return to the operating screen.

Remember to save any changes.

Heater Security ModeThis feature will over-ride the Heater / Table interlock to allow the table to be raised when the heater is still in the forward position. This feature must only be used with very shallow moulds. Mould height must be verifi ed to prevent collision with the heater. This feature may only be used with SA Heater Timer operation or Manual Mode.The sequence triggering for this feature is as follows:• Table UP command is triggered at end of heat time.• The Heater BACK & Vacuum commands are triggered from the Table IS UP limit switch.



User PIN Access Control (Option)The following shows the use of the user access control option:

The main screen will show.Press the key symbol

and the following screen will show.

Press the key symbol

The Default user PIN is 4321The Master PIN is 7931To gain access to the machine press on the user PIN value and enter the default PIN 4321. Press and return to the main menu, the key symbol will show green and the machine may be operated normally. will show green and the machine may be operated

To change the user PIN press the key symbol on the main menu and enter the Master PIN 7931, this screen will open. The master PIN may not be changed.Enter the new pin and return to the main menu. The access control feature may be dissabled by pressing on the enabled button (toggle). Use the master pin to enable / disable.

Enter the new code for the relevant PIN level and press the CHANGE USER PIN button.It is important to ensure PIN changes are controlled. When changing PIN level 4 ensure that records are kept to allow future changes to be managed.Contact Formech if the PIN level 4 is changed and then later lost.

User PIN Access Control - Changing PIN Settings in access level 4The following screen will show when the forwards arrow is pressed after entering the PIN code for access level 4.

Press and return to the main menu,



Fixed Table mode (Option)This is an option to allow the control system to operate with the table permanently UP during the sequence. It is not available with the twin heater option.Pre-stretch and Auto-level are disabled.The fi xed table sequence is as follows: > Clamp down > Heat > Mould & Release > Cooling > Clamp upThe sequence timing will change as follows:Vacuum and cooling are triggered when the ‘Heater IS Back’. Normal cooling delays apply.Release is triggered at the end of the vacuum time.The clamp is raised at the end of Release or the end of the Vacuum time if Release is not applied. The clamp will rise after this time.End cycle is when Clamp is UP.

InterlocksHeater is allowed forwards when table is UP

RESETTable UP is commanded instead of table down and the sequence will start with the table UP.

Fixed Table Mode AccessThe feature may be enabled in the Table settings screen and applies a visual lock on the table button on the operation screen.


Machine Adjustments and Settings

Other controls and user adjustments

Speed AdjusmentThe Plug assist down speed, the table up speed and the table down speed are controlled by the speed adjustments fitted to the front of the machine. Adjust these to assist with synchronisation of the plug and release functions. The Vacuum flow may be adjusted using the Vacuum lever valve. Other speed adjustment is performed by using the speed controllers mounted on the cylinder ends or valves.

Clamp Frame rear spring adjustmentThe clamp frame is spring loaded at the rear.

The loading of the springs may need to be adjusted, for example, when using thinner or thicker plastics materials to assist with correct clamping.

Panels will need to be removed when making this adjustment, isolate the machine power before removing any cabinet panels

Cooling Fan AdjustmentThe cooling fans may be adjusted to give the correct direction for cooling of the vacuum forming. Loosen the nut and screws in the pivot block to rotate and position the fan on the fan post and fan plate.

Plug assist mechanical stop (Option)The plug assist is guided by the external guide bars. Threaded screws on either side of the plug cylinder allow adjustment of a mechanical lower stop. Ensure the plug is UP and adjust the 2 large nuts to the required lower stop level. Ensure that the stop nuts are at the same level on each side of the cylinder.

Clamp insert reducing barsThe clamp frame has a slot to ensure correct vertical alignment of the reducing bars.To change the reducing plate, raise the clamp frame, remove all the retaining screws for the reducing plate and lift the plate out. Ensure that safety procedures are followed for lifting and handling. Fit the required reducing plate and replace all the fixing screws. Lower the clamp frame until it is 10mm from the aperture plate. Remove the screws of the short internal clamp insert and remove the bar. Remove the screws for the rear insert and adjust the position to align with the new clamp frame. Replace the screws and fit the other new bar and fit the screws. Check the frame alignment and tighten the screws. Formech can produce reducing systems for any size aperture.


Machine Adjustments & Settings

Fixing mould toolsThe aluminium mould cooling bolster has internal water channels and care must be taken to ensure holes avoid the water channels shown. All dimensions in mm. The internal water channels are 10mm diameter. Take care to avoid the water channels and ensure holes do not pass through the bolster; this will eliminate the chance of vacuum air leakage. The bolster thickness is 22mm. Where a bolster is not fi tted a similar thickness plate is fi tted without water channels.

Table Height Adjust (Lower Limit)The Mould Table lower position limit switch is mounted on an adjustment post next to the Table cylinder. Access is via the front door. To adjust, drive table up to the required height in manual mode, open the front door and loosen the limit switch retaining screws to slide the switch up so that it is just triggered by the table guide bar above. Tighten the screws, close door and reset the guard. Drive the table up then down to check that the desired height setting is correct. Readjust as required.



Table Height Adjust (Upper Limit)If negative moulds are being used, the table top limit switch will require adjustment. The purpose of the top limit switch is to trigger the vacuum function and subsequent outputs so if the table fails to reach this sensor then such functions will not be initiated. Fit the negative mould tool to suit the aperture plate (the aperture plate may require removal to perform this). Ensure the tooling allows for vacuum sealing. Drive the tool fully up, open the front door and adjust the top cylinder sensor down until the indicator light shows (mounted on the front of the table cylinder). Aim to position the sensor in the centre of the sensed range.

Pyrometer Air Pressure (Option)The pyrometer has air cooling to prevent over-heat, it is important that this air supply is ALWAYS connected. A pressure tank is provided to give the pyrometer air system a short term reserve supply if the main air supply is disconnected. If the reserve air supply pressure falls then the heaters will turn off and the symbol will show on the control screen. The pyrometer air supply may be adjusted using the regulator situated on top of the reserve tank.

Reel Feed (Option)The Reel Feed System comprises Reel bar, supports and stand. To fi t a reel of material (B), remove the reel bar (A) and place it on the fl oor, remove one set of the reel holders (C to E). Slide the bar through the reel core and fi t the reel insert (C), the nylon spacer (D) locking the reel fi rmly in place with the end collet (E) by pushing in the direction F and holding the locking assembly at the other end of the reel.. Adjust the position of the reel by moving the whole assembly along the shaft to suit the machine aperture position. Mount the complete reel bar on the stand. The machine is fi tted with clutch rollers and material guides. Position the rollers at the sides of the material and slide the material guides up to the material.Fit the reel tensioning strap over the groove of the reel insert(C) to control the over-run of the reel when being pulled through. Additional weights or a second strap may be fi tted to the other side.

A pressure tank is provided to give the pyrometer air system a short term reserve supply if the main air supply is disconnected. If the reserve air supply pressure falls then the heaters will turn off and the symbol will

A clutch roller is fi tted to the machine material inlet to prevent the material from slipping back; lift the clutch roller bar to release the material.



Mist (Option)The spray mist cooling feature assists with cooling of finished parts. Water is applied to mist atomisers in front of the fan units. The water supply is drawn from a reservoir and formed into a mist using compressed air. Each mist nozzle will have a water and air connection. The air is activated by a valve SV12. The water reservoir is kept topped up by a ball valve situated in the tank. Mains water is supplied to the valve using the connection on the rear of the machine.The effectiveness and flow of the water mist is dependent the atomiser settings and water pressure determined by the water level and the height of the atomisers mounted on the fan unit. If it is found that there is excessive dripping from the atomisers then the reservoir tank will need to be lowered and / or the fan units raised. The mist flow rate may be adjusted by turning the needle at the rear of the atomiser.


Fault Diagnostics / Maintenance

Before any maintenance work is carried out, both electrical and air supplies must be locked in the OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage.

That person is responsible for ensuring that the machine is in a safe condition before allowing services to be restored.

ElectricalThe PLC relies on the limit switches continually reporting correct mechanical positioning information. Although extremely robust, limit switches and cylinder sensors are frequently activated. The security and operation of switches and sensors require checking during periodic maintenance.If a limit switch is not operating properly, nor will the PLC operating system. Limit switch faults may stop the auto cycle and may prevent the machine functions completely.A logical approach to detecting the fault begins with an exact appraisal of the fault scenario.Much time can be wasted looking in the wrong areas for a problem that, when found, was obvious. Assessment of the fault will entail understanding which interlocks operate to prevent further actions.

Software interlocksThere are several interlocks that will prevent the collision of mechanical components, these are specified below:

COMMAND / FUNCTION CONDITIONSClamp DOWN Command Heater must be BACKHeater FORWARD Command Clamp must be DOWN, Table must be DOWN, Plug must be UPAuto-level Function Heater must be FORWARDPre-stretch ON Command Heater must be BACKPlug DOWN Command Heater must be BACK, Clamp must be DOWNPlug UP Command Clamp must be DOWNTable UP Command Heater must be BACKClamp UP Command Heater must be BACK, Plug must be UPMist ON Heater must be BACK

The position of moving parts is monitored by sensors & limit switches fitted to actuators. If expected movements fail to occur then check the relevant actuator sensors are being triggered correctly. The Heater Security feature is designed to allow the table to be driven UP when the heaters remain forwards and hence the Heater /Table interlock is over-ridden. Ensure the mould tool is less than 60mm high when this feature is being used.





HeaterThe flexible cable chain between the heaters and the control cabinet contain a number of heatproof power and thermocouple cables. Due to the continual motion of the heater these may eventually suffer from fatigue and require replacement. Only the correct grade of cable should be used, and the work carried out by a skilled technician.The Quartz heating elements should be periodically inspected for damage and to make sure that they are securely mounted and that the electrical connections are tight. The same applies to ceramic elements (Option).For the reasons stated the elements, associated cables, connectors, fuses are specifically excluded from our standard warranty.

Replacement of heating elements - Top heaterEnsure the power is isolated and the air supply is switched off. Remove any side panels to allow access. Remove the heater cover relating to the suspect problem element. Locate the problem element. Top heater elements are rated at 230V with various power ratings. When a faulty element is discovered, disconnect it and remove the clips. The fitting of the new element is in reverse.It is recommended that the heater tray electrical connections are periodically checked. This requires systematic tightening every terminal screw. This procedure must be performed within the first 6 months of use or sooner if usage is heavy. Repeat this procedure every 12 months thereafter.

Auto-Level SensingThis machine is fitted with an automatic sheet levelling system. An optical sensor directs a beam of infrared light across the machine. The system comprises of a transmitter and receiver. If the beam is broken air is pumped into the machine cabinet under the plastic lifting it until beam transmission is re-established. Through beam sensors are reliable. The optical windows positioned in front of the sensors on the inside of the mould box may need periodic cleaning.Faulty auto-level sensing would cause the air to blow continuously into the vacuum cabinet.Verify the signal at the PLC data input 4 of PLC module 2. Refer to electrical drawing ITEM 13.





VacuumThe vacuum circuit requires very little maintenance. The vacuum pump oil level needs to be checked occasionally depending on use and the vacuum pump filter mounted on top of the pump should be inspected occasionally and blown clean or replaced.

Loss of vacuum may be caused by worn or damaged seals around the perimeter of the table. These are regarded as a consumable part and should be replaced when signs of wear become apparent. Other causes of vacuum loss are loose or damaged flexible hoses and fittings.The vacuum tank is fitted with a drain plug. Drain the tank if it is suspected that any moisture as been drawn into the tank.

THE VACUUM TANK IS FITTED WITH A NON RETURN VALVE TO PREVENT IT FROM EVER BECOMING PRESSURISED. UNDER NO CIRCUMSTANCES SHOULD THE MACHINE BE RETURNED

TO SERVICE (AFTER REPAIR) WITHOUT THIS DEVICE. IF ALLOWED TO PRESSURISE THE VACUUM TANK MAY EXPLODE!





PneumaticsProviding there is a good filtered regulated lubricated air supply, using good quality airline oil, maintenance will be minimal. However, a thorough inspection of the machine is necessary from time to time. Any mechanical damage of pipes and fittings should be dealt with before re-using the machine.Always lock air supply OFF and bleed out system air before attempting any maintenance of air system. Excessive oil dripping or air escaping from a cylinder nose bush usually suggests that the seals require replacement. Seal kits are available for cylinders. Internal leaks within cylinders and valves are usually detected when a cylinder creeps into the wrong position or air continually seeps out of the valve exhaust port. Again seal kits can be provided - please specify cylinder / valve number & model when ordering.Other problems that solenoid valves may suffer from are:1) Lack of electrical supply - Check appropriate circuitry2) Solenoid has become open circuit - Replace with new solenoid3) Return mechanism jammed or broken - Dismantle valve to investigate. Replace if required.4) Wet or dirty air supply - Check condition of air compressor and condensate management system.If the machine is to be not used for more than a few hours the compressed air system should be de-pressurised. We strongly recommend fitting a lubricator to the main air supply if the machine is intended to be used for daily production. This will extend the working life of the pneumatic cylinders and valves.Adjust the lubricator such that the oil level drop can be noticed over the course of one days full use. Do not allow excessive amounts of oil to enter the pneumatic system. Many problems can be caused by water in the pneumatic system.

General lubricationBearing housings, slide and rails should be checked periodically, and lubricated when necessary using high temperature lithium grease.

Clamp & Table SealsThese are regarded as a consumable part and should be replaced when signs of wear become apparent. (See section dealing with Vacuum)





Replace a damaged or worn sealTable seal – fitted to the underside of the aperture plate

Remove the existing seal with a sharp knife. Remove as much of the original sealant as possible. Using masking tape, make a frame inside where te seal will go (table) or outside (clamp), apply silicone sealant around the area where the seal is to be placed. Do not be too economical with the glue. Bed down a strip of silicon seal until it is firmly seated in the glue.Do not attempt to stretch the rubber seal, it will contract back to its original size before the glue is dry. Cut the ends at 45 degrees. Continue this process for all 4 sides of the seal. Fill up any gaps in the mitred joints with glue. Place masking tape over the mitred corners to help keep them firmly positioned until the glue is dry. Leave overnight, then remove masking tape and trim any excess glue off with a sharp knife.We supply a kit comprising the necessary seal and glue for the HD686/750.The top frame silicone tube may be cut and sealed with sealant in the same way. It is unnecessary to cut the corners at 45 degrees. Masking is also unnecessary.

CleaningEnsure the inside of the machine and the heater tray is cleared of dust, dirt and debris. Do not allow dirt and loose particles to build up, particularly on the heater tray.

Service SupportIf you are unable to cure any problem relating to your machine, or if you wish to order spare parts please contact us on the numbers and emails shown on the back cover of this manual stating the model HD686 / HD750, the serial number (on the specification plate), and a full description of the fault or parts you need.


Periodic Maintenance

Ongoing routine ‘In Process’ checks & work area housekeeping may be performed during normal operation. Monitoring and reporting of machine performance may allow maintenance requirements to be dealt with before wear, damage or when process problems occur. The following schedule indicates such checks / activities.

Inspection / Check Daily Weekly Monthly AnnuallyAir Pressure set at 5 Bar XMonitor for air leaks XCheck integrity of mould table and clamp frame seals. XTest Emergency stop operation XPerform Safety Light Curtain check before 1st operation. XVisible condition of clamp, table & heater sensors / switches XGeneral safety & housekeeping of overall working environment around equipment.

X

Clamp frame adjustment depending upon material. XMonitor Pyrometer consistence (Options) As required

Check Clamping and Table silicone seals As required

Clean Bottom heater glass (Option) XInspect heating elements for damage XCheck condition of heater drive assemblies. X XReplace / clean vacuum pump filtering. X XDrain vacuum tank. XLubricate major mechanical assemblies. X XInspect Pneumatics system XClean Auto-level & bottom heater safety sensor optics.(Option) XCheck Security of Fan units. X X XFull Formech major service routine – dependant on utilisation X

Areas to be monitoredEffectiveness of process functionalityObservation of sensor functionalityObservation of heating element functionalityFault / event loggingJob data housekeepingGeneral work method housekeeping and safety of self and othersMonitoring for Hazardous & Dangerous situations

The following Periodic Maintenance Schedule summarises the regular maintenance required. Owners, designated responsible people and persons required to perform any level of maintenance / servicing must read this Formech HD686/750 manual thoroughly.Particular attention must be paid to references and notices regarding safety.The maintenance requirements will vary depending on the level of machine utilisation.


Warranty

Reliability and a long service life are synonymous with the Formech brand. However, as with any machinery, certain parts will require periodic replacement.

SealsThe silicon seals applied to the mould table and to the top aperture of the machine (clamp) are seen as being consumable parts, their service life will depend on how the machine is treated and how often it is used.

THE TABLE AND CLAMP SEALS ARE NOT COVERED BY OUR WARRANTY.

Heating ElementsThe infra-red heating elements supplied with this machine are manufactured from Quartz & Ceramic (Option) material and are very brittle. A shock to the machine may break an element. Interlocking systems are built into the machine to prevent a mould being pushed up into the heater and damaging the elements. The heating elements contain a length of resistance wire internally which becomes extremely hot when electricity is applied. The wire expands and contracts as it heats and cools. Eventually, due to the continual expansion and contraction, the wire will fracture and a new element will be needed. This may take a decade or more. Alternatively it could happen as a result of an impact or shock. Because of this we are unable to apply our standard warranty to Quartz & Ceramic heating elements.

THE HEATING ELEMENTS ARE NOT COVERED BY OUR WARRANTY.

Vacuum SystemThe vacuum system on this machine is relatively uncomplicated but uses high quality components throughout. The life expectancy of the vacuum system will be compromised by the ingress of dirt, dust, liquid etc.

THE VACUUM CIRCUIT INCLUDING THE VACUUM PUMP WILL NOT BE COVERED BY OUR WARRANTY IF THEY ARE FOUND TO BE BLOCKED WITH FOREIGN MATTER OR CORRODED BY THE INGRESS OF LIQUID.


Electrical Schematics (Index)

Electrical Schematic 1 HD686/750 Block SchematicElectrical Schematic 2 HD686/750 Safety Block SchematicElectrical Schematic 3 HD686 Power distribution 380-415VElectrical Schematic 4 HD686 Power distribution 208-230VElectrical Schematic 5 HD750 Power distribution 380-415VElectrical Schematic 6 HD750 Power distribution 208-230VElectrical Schematic 7 HD686/750 Low Voltage Protection 380-415VElectrical Schematic 8 HD686/750 Low Voltage Protection 208-230VElectrical Schematic 9 HD686/750 Safety Circuit Emergency StopElectrical Schematic 10 HD686/750 Safety Circuit GuardElectrical Schematic 11 HD686/750 PLC / HMIElectrical Schematic 12 HD686/750 PLC Input 1Electrical Schematic 13 HD686/750 PLC Input 2Electrical Schematic 14 HD686/750 PLC PyrometerElectrical Schematic 15 HD686/750 PLC Output 1Electrical Schematic 16 HD686/750 PLC Output 2Electrical Schematic 17 HD686/750 PLC Output 3Electrical Schematic 18 HD686/750 PLC Output 4Electrical Schematic 19 HD686/750 HV Output 380-415VElectrical Schematic 20 HD686/750 HV Output 208-230VElectrical Schematic 21 HD686 Heater Output Zones 1-8 380-415VElectrical Schematic 22 HD686 Heater Output Zones 1-8 208-230VElectrical Schematic 23 HD686 Heater Output Zones 9-16 380-415VElectrical Schematic 24 HD686 Heater Output Zones 9-16 208-230VElectrical Schematic 25 HD750 Heater Output Zones 1-8 380-415VElectrical Schematic 26 HD750 Heater Output Zones 1-8 208-230VElectrical Schematic 27 HD750 Heater Output Zones 9-16 380-415Electrical Schematic 28 HD750 Heater Output Zones 9-16 208-230VElectrical Schematic 29 HD686 Quartz Heater Wiring & Zone Layout 380-415VElectrical Schematic 30 HD686 Quartz Heater Wiring & Zone Layout 208-230VElectrical Schematic 31 HD686 Ceramic Heater Wiring & Zone Layout 380-415VElectrical Schematic 32 HD686 Ceramic Heater Wiring & Zone Layout 208-230VElectrical Schematic 33 HD750 Quartz Heater Wiring & Zone Layout 380-415V & 208-230VElectrical Schematic 34 HD750 Ceramic Heater Wiring & Zone Layout 380-415V & 208-230V


Electrical Schematic 1




































































Parts Listing

2 Quartz Element HD686 Heater 500 FSQ 230V16 Quartz Element HD686 Heater 400 FSQ 230V1 Quartz Element HD686 Heater 250 HSQ 230V7 Quartz Element HD686 Heater 200 HSQ 230V4 Quartz Element HD750 Heater 500 FSQ 230V

12 Quartz Element HD750 Heater 400 FSQ 230V5 Quartz Element HD750 Heater 250 HSQ 230V3 Quartz Element HD750 Heater 200 HSQ 230V

16 30A 2 pole Ceramic block Heater 30A Ceramic Block2 Cable 1.63mm Solid Heater DG 1.63mm

55 Cable 1mm Heater SIFGL 1mm4 Cable White, Blue 2.5mm Heater 2.5mm SIFGL White & Blue4 Cable Silicone G/Yell 2.5mm Heater 2.5mm SIF G/Y3 Glass fibre Sleeving Heater S10 6MM4 Heater idle spring Heater 3241108 Bearing, KLNJ 1/2" Heater KLNJ 1/2"4 Wheel Idler bearing Heater 608ZZ1 Cable Chain Heater BSR300-A050-0801 Cable Chain bracket set Heater BAG300-A050-K001 4P Isolator, 40A (380-415V) Ctrl KM 4P 40A1 3P Isolator, 40A (208-230V) Ctrl KM 3P 40A3 MCB 16A Ctrl HAGER 16A TYPE B1 MCB 10A (208-230V) Ctrl HAGER 10A TYPE B2 MCB 6A Ctrl HAGER 6A TYPE B1 MCB 6A 3 pole Type B Ctrl HAGER 6A Triple TYPE B5 20mm terminal fuse holder Ctrl 2002-16112 Fuse 1A Cab fan , 240v op ctrl Ctrl 20mm fuse 1A2 Fuse 2A, plc/ HMI, PYRO Ctrl 20mm fuse 2A1 Fuse 4A 24vdc ctrl Ctrl 20mm fuse 4A1 24V SMPSU, 4A Din Mounted Ctrl MDR-100-241 1000 light guard 630mm Ctrl 012-1041 Light Guard Controller MFU Ctrl 011-1601 E Stop Controller Ctrl XPSAC51211 PLC Ctrl 750-852 2 PLC 8 Ch IP Module Ctrl 750-4304 PLC 8 Ch OP Module Ctrl 750-5301 PLC End block module Ctrl 750-6001 PLC Supply module Ctrl 750-602

HD686/750 Major Component Parts & Options


Parts Listing

2 PLC Supply module inc fuse holder Ctrl 750-6011 HMI MT-8100iE Weintek 10" Ctrl MT-8100iE1 RJ45 lead 5m GREY Ctrl 557-4241 RJ45 lead 1m GREY Ctrl 556-3421 RJ45 socket, panel mount Ctrl 782-07912 Cabinet fan Ctrl 37-91152 Cabinet grill Ctrl 37-08781 Contactor 24VDC Ctrl DILEM-10-G 24V1 Contactor overload, 4-6A Ctrl ZE64 Relay Ultraslim single pole 6A, 24V Ctrl 38.51.7.024.00501 2P Relay Base 97.02 Ctrl 97.02.SPA1 24VDC 2P Relay Ctrl 46.52.9.024.00402 Snubber Ctrl XEB12012 235W Fan Ctrl AWCL160SI

16 10A SSR Ctrl G3NA-210B4 2P Relay Base 95.05 Ctrl 95.05 SPA BLUE4 Forcibly guided 2P 24VDC Relay Ctrl 50.12.9.024.10001 Beam Sensor Ctrl CX 411-P (Sun X)1 Table down switch Ctrl 436-03904 Reed switch Ctrl P494A0021300-A00, 1 Safe Switch Ctrl XCS PA5911 Safe Switch Activator Ctrl XCS Z121 BM25 elbow Pod B\M25\902 SP25 M25 Pod SP25\M25\B1 SP25 Pod SP251 Blue Illum. Pushbutton Pod ZB4 BW361 Illum. Switch Body 1 N.O Pod ZB4 BW0611 24V Lamp, 83ma Pod 105-1021 E Stop Button Pod ZB4 BS541 E Stop Contact block, NO/ NC Pod ZB4 BZ1051 ESTOP Legend Pod ZBY 93301 40mm Pressure gauge Pod B001F146A1 40mm Vacuum gauge Pod B001F139A2 4mm to 1/8" elbow female fitting Pod CDPLF 0401N1 Regulator / Filter 1/2" Pnumo M-CFR60-4W4 Flow Regulator Panel Mount 10mm Pnumo CDNSFB10N1 Lever ball valve 1/2" Vac BV-2090-08, BV12-083 1/2" to 12mm Elbow hosetail Vac N-WES12R1\2"



Parts Listing

1 2/2 Valve, 1/2" Pnumo SCE 210A15, 230V/50hz1 2/2 Valve, 1/2" Pnumo SCE 210A15, 230V/50hz1 1/2" Silencer Pnumo A780 1/2"1 2/2 Piston valve, 1/2" Vac E290A3841 3/2 Valve for above Pilot 24vDC Vac 189 00 033 D2 24VDC1 3/2 valve 1/4" 24vdc Pnumo SCG 551 A 005MS 24vdc2 3/8" Silencer Pnumo 346004093 ISO 1 Sub-base Pnumo 355000881 Manifold End Plate Pnumo 355000871 ISO 1 5/2 Valve E/S Pnumo 541910232 ISO 1 5/3 Valve W1 Pnumo 541910285 Pilot Solenoid Pnumo 18900001D27 Size 22 connectors - supressed Pnumo 881 22 405 24V dc1 Cylinder 50bore x 850 Pnumo G453A5SK850A001 Cylinder 100bore x 350 Pnumo G453A1SK-350-A002 Cylinder 63bore x 530 Pnumo G453A6SK-530-A002 Clevis AP2 63 Bore Pnumo 434 00 0184 Speed controller 1/4 to 8mm Pnumo CDNSC08022 3/8" Cylinder Blocking Valve Pnumo 346 02 4511 Vacuum Pump Pnumo U 4.204 1/2" Wire reinforced suction pipe Vac P-AM012-102 Clevis AP2 40 Bore Clamp 435 00 0172 Clamp pivot bearing 2 holes Clamp UCFT202 Spring, Red, 25 OD, 12.5ID, 63mm Clamp 9-1610-2604 Foot M16 Mainframe 4907/3/C3 Silicone tube Mainframe PSIL4x25 8mm x 12mm Silicone Seal Strip Mainframe SE515 12X81 High Modulus Silicone Sealant Mainframe HMA1004 Door key catch Mainframe 450-99551 Key, catch Mainframe 341-02366 Hinge Mainframe 702-78311 Mesh Mainframe 686 MESH



Parts Listing

2 Ceramic Element HD686 Option Heater 500 FSC 230V16 Ceramic Element HD686 Option Heater 400 FSC 230V1 Ceramic Element HD686 Option Heater 250 HSC 230V7 Ceramic Element HD686 Option Heater 200 HSC 230V4 Ceramic Element HD750 Option Heater 500 FSC 230V

12 Ceramic Element HD750 Option Heater 400 FSC 230V5 Ceramic Element HD750 Option Heater 250 HSC 230V3 Ceramic Element HD750 Option Heater 200 HSC 230V1 Pyro unit & Jacket Heat Pyro RAYMI3 10L TH CB81 2 Ch T/C module Heat Pyro 750-4691 Regulator 1/4 Heat Pyro M-R55M-2W1 1/8" gauge pyro 0-30psi Heat Pyro YY003040B2D1 8mm tube to 1\4" male Check Valve Heat Pyro CDCVPC0802N1 1/4" Relief valve 9 bar Heat Pyro W60006-9.01 Tank pressure switch Heat Pyro 398-70451 Tank pressure 24L Heat Pyro BPB04711 Pyro unit Cool Pyro RAYMI3 10L TS CB81 Bolster plate 7/8" 730 x 652 Bolster HD/TF 686 750 BOLSTER1 Cylinder 63 bore x 600 Plug G453A63SK-600-A001 3/8" Cylinder Blocking Valve Plug 346 02 4511 ISO 1 Subbase Plug 355000881 ISO 1 5/3 Valve W1 Plug 54191028 clamp table2 Spring Plug SP12581 Flow Regulator Panel Mount 8mm Plug CDNSFB8N1 Limit Switch Plug 308-18442 1/8" AL 04- A Brass Atomising nozzle Mist W 131 81 04 151 2/2 Valve, 1/2" Mist SCE 210A15, 230V/50hz1 Float Ballvalve 1/2in Mist P0010451 Float Mist P0010992 Neopreme Washer 75 x 12 x 25 Reelfeed KP 75 12 251 Clutch bearing Reelfeed RCB0812141 Roller bearing Reelfeed SR1212

HD686/750 Options Parts

If you are unable to cure any problem relating to your machine, or if you wish to order spare parts please contact us, stating the model (HD686 / HD750), the serial No. (on specification plate) and a full description of the fault.


E C Machinery Directive2006/42/EC

Declaration of conformityWe hereby certify that the machinery stipulated below complies with all the relevant provisions of the EC Machinery Directive and the National Laws and regulations adopting this Directive. Modifications to this machinery without prior approval from the undersigned will render this declaration null and void.

Machine Description: Vacuum Forming MachineMachine Function: Thermoforming of Plastic SheetModel / Type: HD686/750Serial Number: Date of Manufacture: Is in conformity with the provisions of the following other EC Directives: 2004 / 108/EC – EMC 2006 / 95/EC – LVD

Technical File Compiled by: Andrew Berry at address below.

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Significant harmonised standards applied: EN ISO 12100 : 2010 EN ISO13849-1:2006 EN 60204 –1 : 2006 EN 12409: 2008______________________________________________________

Signed Date: Name: Paul VukovichPosition: Managing DirectorBeing the responsible person appointed by the manufacturer

FORMECH INTERNATIONAL LTDUnit 4 Thrales End Business Park, Thrales End Lane, Harpenden, Hertfordshire, AL5 3NS

EC Certificate

Formech International Limited, Unit 4, Thrales End Farm, Thrales End Lane, Harpenden

Hertfordshire AL5 3NS, United Kingdom


For Parts, Service & Technical Assistance UK, Europe and Rest of the World

Telephone: +44 (0) 1582 469 797Fax: +44 (0) 1582 469 646

[email protected]

For Parts, Service & Technical Assistance North and South America

Telephone: [email protected]

Formech International LimitedUnit 4, Thrales End Farm, Thrales End Lane, Harpenden, Hertfordshire, AL5 3NS U.K.Tel: +44 (0)1582 469 797 Fax: +44 (0)1582 469 646Email: [email protected]

Documents

Fully Auto Vacuum Forming Machine - formechinc.com · the vacuum forming process such as: food products, all types of particles, powder, dust,