Formech 300xq Service manual

l

....

Formech

Installation,

Operating

and

Service

Manual

@

If

I

User Manual 1

Contents

Safety

......................................................................................................................................

..

..............3

Intro

duc

tion

and

initial

as

sembly

...........................................................................................................6

Optional

ex

tras

........................................................................................................................................7

General

Arrangement

............................................................................................................................. 8

Operating

pro

c

edures

..........................................................

..

.................................

..

............................

10

BASIC OPERATION .............................................................................................................................

11

F.A.Q..

..

...........................................

..

....................................

..

...............................................................

13

Warr

a

nty

...............................................................................................................................................

14

Se

r

vice

I

Repair

.....................................................................................................................................

15

A. REPLACING

SEALS

.........................................................................................................................

15

B. REPLACING A HEATING ELEMENT.................................................................................................

16

C.

ELECTRICAL

TROUBLESHOOTING..................................................................................................

17

D.

VACUUM

/

PRESSURE

TROUBLESHOOTING ...................................................................................

19

Schematics

.................................................................................................................

..

....................... 20

1

....

P

age

2

......

Safety

Thank you

for

choosing Formech.

Please

read and follow the below safety instructions before attempting

to

install or operate your machine.

&.

Ill-

Only use

the

machine

for

vacuum forming plastic.

It

is

not

intended

for

any other purpose.

Ill-

Read

and understand all

of

this user manual.

Ill-

This

is

a 'single person operating' machine.

Ill-

Do

not

operate the machine until you have been trained and are fully conversant with it.

Ill-

Users

of

this machine should complete regular competence tests.

Ill-

Check yoursupply voltage and frequency. Make sure

it

is

compatible

with

your machine. Your

machine's electrical specification

is

on

the

plate on

the

Left hand side.

Ill-

You

must ensure

that

the

machine

is

properly earthed and fused.

Ill-

If your machine

is

not

equipped with a moulded mains connector then note that:

The earth wire

is

GREEN

with

a

YELLOW

stripe.-=i::===r

The live wire

is

BROWN

The neutral wire

is

BLUE

111!!!1

Ill-

Only suitably qualified personnel should make electrical connections

..,.

Turn

off

the machine and disconnect

the

power supply when the machine

is

not

in

use

.

..,.

The heater and pump

on

this model are

not

intended

to

be

left

running indefinitely.

Ill-

This machine

is

fitted

with a dry running vacuum pump.

Do

not

lubricate.

Do

not

allow any liquid

to

enter the vacuum system. Ensure

that

moulds are properly sealed

to

prevent ingress

of

dust

into

the

vacuum circuit. Severe damage may be caused

if

the

above

is

not

observed.

Ill-

Note the safety warning labels situated

on

the

front

and rear panels. Never remove any warning

labels from the machine.

..,.

Never remove any panels unless

the

electrical supply

has

been isolated.

..,.

Ensure

that

the area surrounding

the

machine

is

clean and frequently cleared

of

finished product and

any scrap.

Ill-

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.

Page

3

Safety

Hazards specific

to

this

machine.

It

is

vital

that

any person using this machine and

the

person(s) responsible

for

the

health &safety is made

fu

lly

aware

of

the

potential hazards

that

could arise

from

the

use and misuse.

1. Electric shock.

This machine

uses

Voltages up

to

240Vac.

NEVER

ATIEMPT

ANY

REPAIR

UNLESS

THE

ELECTRICAL

SUPPLY

DISCONNECTED

.

ONLY

SWITCH

ON

WHEN

ALL

COVERS

HAVE

BEEN

REPLACED.

ONLY

A

QUALIFIED

ELECTRICAL

TECHNICIAN

MAY

WORK

ON

ANY

PARTS

CARRYING

MAINS

VOLTAGE

AND

SH

OULD

BE

RESPONSIBLE

FOR

ENSURING

THATTHE MACHINE

IS

IN

A

SAFE

CONDITION

BEFORE

ALLOWING

SERVICES

TO

BE

RESTORED.

,A

2. Burning.

Parts

of

thi

s machine reach temperatures

in

excess

of

300°

C.

NOTE

THE

'HOT

SURFACES'

S

AFETY

LABELLING

ON

THE

HEATER

&

HEATER

GUARD

.

SPECIAL

PRECAUTIONS

MUST

BE

TAKEN

TO

ENSURE

THAT

ONLY

THE

MACHINE

OPERATOR

IS

IN

THE

OPERATING

AREA

DURING

USE

.

USE

PERSONAL

PROTECTIVE

EQUIPMENT

SUC

H

AS

GLOVES

WHEN

TESTING

THE

HEATED

PLASTIC,

HANDLING

HOT

VACUUM

FORMED

PARTS

, MANUALLY

ASSISTING

THE

FORMING

PROCESSS

AND

TOUCHING

HOT

SURFACES

.

INFRARED

RADIATION

IS

EMITIED

BY

THE

QUARTZ

HEATERS,

ENSURE

THAT

ANY

EXPOSURE

TO

THIS

TYPE

OF

RADIATION

IS

SHORT

OR

COMPLETELY

AVOIDED

.

WAIT

UNTIL

THE

MACHINE

HAS

COOLED

DOWN

BEFORE

SERVICE

WORK

COMMENCES.

3.Toxic Fume Inhalation.

When plastic sheet

is

heated fumes will be given

off

.

ENSURE

THATTHE MACHINE

IS

POSITIONED

IN

AN

ADEQUATELY

VENTILATED

PLACE.

IT

IS

THE

RESPONSIBILITY

OF

THE

OWNER

OR

DESIGNATED

RESPONSIBLE

PERSON

FOR

HEALTH

AND

SAFETY

TO

ASSESS

THE

RISKS

ASSOCIATED

WITH

ANY

DANGEROUS

FUMES

GIVEN

OFF

AND

TO

DETERMINE

ANY

NECESSARY

PRECAUTIONS

REQUIRED

SUCH

AS

FUME

EXTRACTION

PRIOR

TO

USE

.

4.

Injury

from

Trapping.

CARE

IS

REQUIRED

WHEN

OPERATING

THE

CLAMPING

FRAME

TO

ENSURE

THAT

FINGERS

OR

HANDS

ARE

NOT

TRAPPED

.

KEEP

HANDS

CLEAR

OF

THE

HEATER

RAILS

WHEN

PULLING

THE

HEATER

FORWARDS.

5. Fire.

RISK

OF

FIRE

AS

A

RESULT

OF

HEAT

AND

PLASTICS

PRESENTS

AN

EMERGENCY

SITUATION.

ENSURE

F

IRE

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

.

Page

4

-

1

'

l

-

'

.._.

-

L

-

Safety

6. 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

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

TOP

OF

THE

HEATER

OR

TOP

OF

THE

HEATER

GUARD

TO

STACK

PLASTICS

OR

OTHER

MATERIALS.

DO

NOT

USE

THE

MACHINE

TO

STACK

OR

LEAN

ITEMS

AGINSTTHE

SIDES

.

DO

NOT

USE

ANY

OTHER

PART

OF

THE

HEATER

TO

MOVE

THE

HEATER

FORWARDS

AND

BACKWARDS

OTHER

THAN

THE

HEATER

HANDLE

.

DO

NOT

USE

OR

MODIFY

THE

ELECTRICAL

POWER

IN

THE

INTERNAL

WIRING

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

.

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.

Transportation /

Positioning

The 300XQ will be supplied strapped

to

a Pallet

or

in a crate. The machine may unpacked and placed on a

bench, table

or

300XQtrolley.

Ensure

that

the

structure,

size

and load bearing capacity

of

the

bench

or

table

is

sufficient

for

the

machine weight. A minimum

of

2 persons are required

to

lift

the

machine. In

the

case

of

the

300XQtrolley, ensure

that

the 2 machine retaining screws are fitted

to

the underside

of

the

trolleyI Machine.

Noise

emissions

Noise emissions on

the

Formech 300XQ are less than 70dB(A).

Machine

storage

The Formech 300XQ

must

be

stored in a

dry

environment.

Page

5

Introduction

and initial

assembly

The Formech 300XQ

is

a highly versatile, manually operated Vacuum Forming Machine

that

will

pro

duce high

definition mouldings in

up

to

6mm thick material.

It

is

intended

for

use only

for

the

Vacuum forming

of

plastics

components and

for

the

blowmoulding

of

heated plastics.

Your Formech machine

is

supplied

with

lx

Electrical cable

lx

Installation/Operations/Repair

Manual

lx

Table lever!•l

!

•l

The 300XQmachine

is

fully assembled except

for

the

table lever.

lx

EC

Certificate

of

conformity

lx

Table mesh

ENSURE

THATTHE

TABLE

LEVER

IS

TIGHTLY

SCREWED

INTO

THE

CRANK

MECHANISM

ON

THE

RIGHT

HANDSIDE

OF

THE

MACHINE.

IF

OPERATED

WITH

THE

LEVER

LOOSENED

YOU

MAY

DAMAGE

THE

CRANK

OR

THE

HANDLE

.

--

Page

6

-

I

-

Optional

extras

The following items can be purchased

for

your

300XQvacuum forming machine

1. Machine

trolley

with

castors

2.

Reducing windows 3. Blow mould

window

4. Service kit

1. The Formech machine

trolley

allows you

to

easily move

your

300XQmachine. The 2 locking castors assure

the

trolley remains in position all

the

time

. Underneath there

is

also space

to

store plastic material and

moulds.

2. Formech have available a standard sizes

of

reducing plates. This reducing plate allows

the

use

of

plastic

size

254mm x 228mm. Formech can also produce special size reducing windows. For more information please

contact

our

sales department.

3. You can use

your

vacuum forming machine

to

do

blowmoulding

by

fitting

aspecial circular reducing

window

to

your

machine. The maximum diameteryou will get on

the

300XQ

is

300mm. For

more

information

please contact

our

sales department.

4.

It

is unlikely

that

you will need

to

service

or

repairyour machine

for

many years provided you

follow

the

maintenance information contained in this manual; however

the

table and clamp seals, which are considered

to

be consumable items, will need

to

be replaced dependingon

the

usage

of

the

machine. Thereforethis

kit

contains

the

essential consumables (seals and pumpfilter)

to

ensure agood performance

of

your

machine

year on year.

Page

7

General Arrangement

E

LECT

RI

CAL

SPECIFICATION

Stanoord Volage:220.240

Stanoordfrequency. 5016Giz

Stanoord Max Power· 2

3Kw

...

1.

Spedca•on

pla

te

2

Power

inlet receptade

3

Power

switch

~

/

OFF

4. Cklmpframe

5 Materel

danps

6. Heater

Box

7 Vacuum\pressurevalve

8 Table

leVEJ

9.

Control

pai

el

10.

Pt.mp

switch

ON

I OFF

11

Ar

ootput

MECli/lllllCALSPEORCATl

ON

DO

NOT

CONNECT

AIR

SUPPLY

HERE

Stanoord material

StZe

450'ml

x300mm (18"x

12

'1

Maximum fammgarea

430rrvn

x

20011YTl

(16.9"x11 02'1

Malimum

de~

d

aaw

18511YTl

(6

71

8")

Overal

wOtti

64~m

(251

/4")

Overal height 53crnm

(21

'1

Overal laigth 1

OOOmm

(

39

3\8")

wagit

65kg (145ibs)

1. Specification Plate.This states

the

e

ss

ential machine data &

CE

marking.

2.

Power

Inlet

receptacle.The machine issupplied complete

with

a

power

cable

that

plugs

into

thi

s receptacle

and then

into

asuitable

power

socket.

If

your

machine

is

aspecial voltage

or

frequency

then

it

may be

supplied

with

a lead

not

terminated

into

a mains plug.

See

Safety section

at

the

beginning

of

this manual.

Note

the

safety labelling.

3. PowerSwitch ON/OFF. This

is

the

main switch. When in

the

OFF

position

pow

er

is

cut

to

all functions.

Before commencing any repair

work

always remove

the

mains lead

from

the

Power InletReceptacle.

4. Clamp Frame.This holds

the

plastic material in position during

the

forming and release processes.

5.

Material

Clamps. These clamps fix

the

Clamp Frame

firmly

down. After placing

the

plastic

under

the

clamp

frame

the

material clamps are adjusted

by

tightening

or

loosening

the

orange

nutlet

s.

The levers are pulled up

until they are fullyover-centre. Adjustme

nt

may onlybe carried

out

while

not

underpressure. The rear

of

the

clamp frame is selfadjusting.

6. HeaterBox. This carries

the

heating elements and

is

drawn forward

by

pulling

the

centrally mounted

handle.

7. Vacuum/Pressure Valve. When

the

vacuum pump

is

running

thi

svalve switches between removing air

from

between

the

mould and moulding during forming (vacuum) and introducing airbetween

the

mould and

moulding

for

finished

part

release (pressure).

Pa

ge

8

'

l

-I

-

l

-

General Arrangement (cont.)

8. Table Lever. When pulled towards you

the

table will rise

to

the

upper limit. A

further

application

of

pressure will lock the table in this po

si

tion. During forming

the

table complete

with

mould

is

lifted intothe

hot

plastic and locked in place

to

ensure a good vacuum seal. At

the

end

of

the

cycle

the

table

is

returned

to

the

lower

po

sition by pushing

the

handle

back

and away.

NOTE

: A mechanical interlock designed

to

prevent a mould being raised

into

the heating elements stops

the

table being raised unless

the

heater box

is

fully

back

.

9. Control Panel.

See

below control panel layout.

10

. Vacuum Pump ON/OFF switch. This turnsthe vacuum pump on and

off

. The vacuum pump evacuates the

air between

the

plastic sheet and the mould.

It

also provides pressure

to

release

the

finished moulding

from

the mould.

11.

Air

pressure outlet. When the vacuum pump

is

running,

the

pressure

is

diverted

to

this outlet.

Thi

s

can

be

used

to

supply

or

run other equipment when

not

being u

se

d

for

vacuum formin

g.

Do

not

block this

outlet

or

attempt

to

connect

air

supply This machine

DOES

NOT

require

air

supply.

12

·

~

• .

.-..

-

"V

A

- -

12

Heater

Zone

l

ayout

13

Heater

standby

leve

l

con

tr

ol

14

.

Zone

powerlevel

controls

15

0

15.

Heater

timer

16. Vacuum Gauge

12

. HeaterZone layout. Pictogram showing the correspondi

ng

zone layout

of

the quartz heater zones.

13. Heater Standby Level (Power

Saving

Feature). The 300XQ

is

supplied wi

th

fast acting heating element

s.

This means

that

when

the

heater

is

not

actually heating plastic

the

power

can

be turned down.

As

the

heater

is

moved

from

the

rear position

the

elements begin

to

heatup

to

the

set powerlevel.

For this feature

to

work effectively

the

power level

at

rest

or

standby must be s

et

to

approx.

30

%.

Fo

r

continuous usage

the

standby level may be set lower.

Fo

r infrequent us

age

it

may be required

for

the standby

level

to

be set higher. For non-

time

critical

uses

the standby level can be set

at

about

10

%.

Although the

plastic may take a

few

extra seconds

to

heat,

the

overall powersaving will be substantial

Safety Notice:

It

is advisable

to

monitor

the

heatingstage

by

makingfrequent observations.

Neverleave

the

machine unattended when actively heatingplastic.

14

. Heater Zone Controls. The 300XQ heater

is

divided

into

4 zones

as

shown by the diagram (12) on

the

control panel.

This

is

to

allow

the

user maximum flexibili

ty

especially when producing mouldings from difficult

moulds or difficult plastics.

It

is

usual

to

turn the centre zone 1 down slightly becau

se

it

gains extra heat from

the other zones surrounding it.

The

back

zone

3 also tends

to

stay

hotter

than

the

front

zone 4 because

the

rear

of

the

machine

is

heated by the heater when

it

is

not

heating plastic. A

key

feature

of

quart.z heating

is

Page

9

the

response time

for

changing

to

different power levels. The zone controllers are highly accurate

and

keep

the

element power level within

1%

of

the

requested setting. Beginners

to

vacuum forming will quickly become

accustomed

to

setting

the

zone controls

for

best results.

15. Digital

Timer

. When producing a quantity

of

mouldings using

the

same mould and plastic

the

heating

time

will

be

nearly constant

for

each one.

In

this

case

the

timer

can

be used. Record

the

heating

time

for

the first

moulding then set

the

timer

(in seconds) using the

UP/

DOWN

buttons

the

buttons. When

the

heater

is

pulled

forward

the

timer

counts down from

the

set

time

and sounds a buzzer when zero

is

reached. The heater

is

then pushed back. The set

time

is

stored until

it

is

altered.

If

you don't want

to

use

the timer, set

the

time

to

zero.

The

timer

has

built in safety features.

If

the

heater

is

forward

for

more than 2 minutes

after

the

timer

has

completed the set

time

the

heater will switch

to

the

standby setti

ng.

If

the

heater

is

not

returned

to

the

standby position aftera

further

2 minutes then the heater will

turn

off

all power

to

the

heating elements.

16. Vacuum Gauge. This

is

situated on

the

top

RHS

of

the

front

panel and gives indication

of

the

vacuum level

achieved at

the

table mould area during moulding.

It

is

usual

to

expect approx

22

"

Hg

I -750mbar

of

vacuum.

If

such

levels are

not

achieved check your mould I table configuration & clamp I plastic

seal

ing.

Reducing Windows

Reducing windows allow

the

use

of

smaller sheet material

for

smaller mouldings. Reducing windows allow

for

better

sheet utilisation.

To

fit

the

reducing

window

.

1. Lift

the

clamp frame.

2.

Place

the lowerreducing window plate on

to

the top

frame aperture

so

that

the corner locating

screws are aligned.

3.

Place

the

top

reducing window plate on the underside

of

the clamp frame. There are folded sections

on

the

front

and rear. The rear edge

has

the larger return and wraps completely around

the

clamp

frame bar. The

front

fold

is

smaller and returns against the

front

clamp frame

ba

r.

The fixing bolt

is

fitted

through

the

clamp frame bar and reducing plate and secured using

the

fixing nut..

See

diagram

below

of

side view

of

thetop

plate fitting.

Rea

r

of

cla

mp

rame

Fron

Side

view

4.

Close

the clamp frame.

Check

alignment

of

top

and bottom plate. Fit the required plastic material on

the

sealed lowerreducing plate. The material toggle clamps will need adjusting so

that

the

clamp

frame

can

be locked

to

achieve

the

necessary clamping pressure.

Page

10

Formech 300XQ Service manual

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