Formech 508DT Service manual

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Formech International Limited
Installation Operating and Service Manual
MODEL: Formech 508DT
Manual Vacuum Forming Machine

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Contents
Safety........................................................................................................................................................................................3
Introduction and initial assembly..................................................................................................................................4
Optional extras......................................................................................................................................................................6
General Arrangement 508FS...........................................................................................................................................7
General Arrangement 508DT..........................................................................................................................................8
Operating procedures......................................................................................................................................................10
F.A.Q........................................................................................................................................................................................22
Warranty...............................................................................................................................................................................22
Service / Repair...................................................................................................................................................................23
REPLACING SEALS .......................................................................................................................................................23
Schematics 508FS............................................................................................................................................................20
Schematics 508DT...........................................................................................................................................................21

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Safety
Thank you for choosing Formech.
Please read and follow the below safety instructions before attempting to install or operate your
machine.
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Do not operate the machine until you have been trained and are fully conversant with it.
Read and understand all of this user manual.
Check your supply voltage and frequency. Make sure it is compatible with your machine. Your
machine's electrical specification is on the plate on the right hand side.
You must ensure that the machine is properly earthed and fused.
If your machine is not equipped with a moulded mains connector then note that:
The earth wire is GREEN with a YELLOW stripe.
The live wire is BROWN
The neutral wire is BLUE
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.
Never remove any panels unless the electrical supply has been isolated.
Note the safety warning labels situated on the front and rear panels. Never remove any warning
labels from the machine.
Only use the machine for vacuum forming plastic. It is not intended for any other purpose.
This is a ‘single person operating’ machine.
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. It is the responsibility of the owner or
designated responsible person to assess the risks associated with any dangerous fumes given off
and to determine any necessary precautions required such as fume extraction. Contact your
plastics supplier to gain information regarding hazardous fumes.
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.
Note the ‘HOT SURFACES’ safety labelling on the heater & heater guard. These areas can become
VERY HOT.
There is a risk of being burnt when handling heated plastics. Always wear suitable personal
protective equipment such as gloves.
Ensure that the area surrounding the machine is clean and frequently cleared of finished product
and any scrap.
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.
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.
Users of this machine should complete regular competence tests.

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Introduction and initial assembly
Your Formech machine is supplied with
1x Installation/Operations/Repair
Manual
1x EC Certificate of conformity
Heater shed
1x Table mesh
ENSURE THAT THE 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.
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Initial assembly
Heater shed
1 -
2 -
3 -
4 -

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508FS only
Counter balance weight
1-
2-
3-
4-
5-
6-

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508FS only
Cooling fan (optional extra)
1 –
2 –
3 –
4 –
5 -
6 -

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508FS only
Cooling fan
7 –
8 –
9 –
10 –
11 -

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508FS only
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Optional extras
The following items can be purchased for your 508FS vacuum forming machine
1. Service kit
2. Reducing windows
3. Blow mould window
4. 508DT machine trolley
5. 508FS cooling fan
1. It is unlikely that you will need to service or repair your 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 depending on the usage of the machine.
Therefore this kit contains the essential consumables (seals and pump filter) to ensure a good performance
of your machine year on year.
2. Formech has available 2 standard sizes of reducing plates for the 508, with apertures of 228 x 204mm
and 432 x 229 mm. 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 blow moulding by fitting a special circular reducing
window to your machine. The maximum diameter you will get on the 508FS is 430mm. For more
information please contact our sales department.

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General Arrangement 508FS
General Arrangement 508DT
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1.Touch screen. One touch screen for the full process with the ability to store programs in the memory.
3. Clamp Frame. This holds the plastic material in position during the forming and release processes.
4. 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 nutlets. The levers are
pulled up until they are fully over-centre. Adjustment may only be carried out while not under pressure. The
rear of the
clamp frame is completely self adjusting.
5. Heater Box. This carries the heating elements and is drawn forward by pulling the centrally mounted
handle.
6. 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 position. During forming the table complete with mould is lifted into the
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 position by pushing the handle back and away.
7. Air pressure outlet. The air pressure outlet lets you power other equipment that require air pressure and
this is created by the exhaust from the vacuum pump. Do not connect compressed air to this outlet.
(508DT only)
7. Specification Plate. This states the model type, electrical supply needed to power the machine & other
essential data.
7. Power connection. You will need to use 2.5mm cable to connect it to a single phase 20amp socket
(508FS only). See Safety section at the beginning of this manual. Note the safety labelling.
7. Mains fuse. This fuse protects the machine and should only be replaced by another of same type and
rating.
7. Power Switch ON/OFF. This is the main switch. When in the OFF position power is cut to all functions.
Before commencing any repair work always remove the mains lead from the Power Inlet Receptacle.
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Operating procedures
BASIC OPERATION
1) The 508FS has built-in default settings which allow the
operator to use the machine without entering values for
the heaters or heating time, if required.
2) Main menu: Allows you to create a new recipe, edit or load an
existing one, or start a vacuum forming process. When the
machine starts, the ‘DEFAULT’ program is automatically
loaded.
3) Press ‘NEW/EDIT’ to access the different settings:
NHEAT SETTINGS
NTIME SETTINGS
4) Under ‘HEAT SETTINGS’ are the settings for the heating
zones and the ‘STANDBY’ feature.
5) ‘ZONES’ displays the layout of the different heating
zones and the corresponding % of heat.
The ‘AUTOLEVEL’ can be activated here if needed.
(available only on the 508FS)
6) To change the selected zone, press the desired zone, and
select the % of heat required. In this example, we will select
60%.

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Operating procedures
BASIC OPERATION (Cont.)
7) The % has now changed.
Repeat this operation for the different zones if necessary.
Once you have set up all the zones, press ‘OK’ on this
screen to come back to the main ‘HEAT SETTINGS’
screen.
8) ‘HEAT SETTINGS’ screen
Press ‘STANDBY’ to adjust the standby setting.
10) Once all the heat settings are done, press ‘OK’ to
come back to the main settings screen.
11) Main settings screen.
You can now change the ‘TIME SETTINGS’
12) ‘FAN RUN’ is an optional extra for the 508FS only.
If you have a fan, press the ‘FAN RUN’ icon and enter
value in seconds.

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Operating procedures
BASIC OPERATION (Cont.)
18) Once you have been through all the different
settings, press ‘SAVE’ to memorise these settings as a
recipe.

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Operating procedures
BASIC OPERATION (Cont.)
19) Allocate a number from 0 to 11.
20) And press the white rectangle to give your recipe a
name.
21) Press ‘KEY’ to change to numerical entries.
22) Press ‘ENT’
23) You can now see your named recipe under the
number you have chosen.
Press ‘SAVE’ to come back to the main menu.
24) Once your recipe is saved, you can ‘RUN’ the
vacuum forming process.

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Operating procedures
BASIC OPERATION (Cont.)
25) Follow the instructions on the red screen.
The next screen will be displayed as soon as the heaters
are brought forward.
26) The timer starts automatically, counting up the time
previously set in the recipe, or it uses the default setting
if the machine has just been switched on.
27) At any time, you can push the heaters back to check
your material. The timer will then stop, and restart once
you bring the heaters forward again, providing the
heater is pushed fully back.
The ‘PRE-STRETCH’ feature can be used at this stage if
needed. (508FS only)
Press ‘START VACUUM’ to go to the next screen.
The heaters need to be brought back and the table up at
this stage.
28) You can stop/start vacuum as required.
29) Once the material has cooled down, ‘RELEASE’ the
material from the mould.
30) ‘FINISH’ the process.
1- You can either go back to the main menu
2- or ‘SAVE TIMES JUST USED’ if the heating time
was shorter than your original settings.

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Operating procedures
BASIC OPERATION (Cont.)
31) ‘MAIN’ brings you back to the main menu, with the
same recipe loaded in the memory.
32) ‘SAVE TIMES JUST USED’ will bring you to the ‘TIME
SETTINGS’ screen
33) ‘TIME SETTINGS’ screen
If the material was ready before the end of the heating
cycle, the PLC will record the new heating time, allowing
you to save it.
34) You can at this stage change the other heating zone
settings if needed + time settings.
36) If you wish to repeat a job you have done in the past,
you can load the recipe, by pressing ‘LOAD’ on the main
menu and then press ‘RUN’.

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Operating procedures
BASIC OPERATION (Cont.)