Formech 508DT Service manual

1
For Parts, Service & Technical Assistance
Telephone: [phone]
Fax: [phone]
508DT/FS
Installation, Operating and Service Manual
.
.
.
Desktop / Floor-Standing
Vacuum Forming
Machines

Manual - Formech 508DT/FS - Rev 3
2
Table Of Content
Safety 4
Introduction 8
General Arrangement 508DT 9
Machine footprint 9
Electrical Specifications 10
Mechanical Specifications 10
Transportation / Positioning 10
Noise emissions 10
Machine storage 10
General Arrangement 508FS 11
Machine footprint 11
Mechanical Specifications 12
Transportation / Positioning 12
Noise emissions 12
Machine storage 12
Electrical Specifications 12
General Arrangement 508DT & 508FS 13
Installation and Inital assembly 508 16
Lifting and Handling - 508DT only 16
Heater Guard - 508DT & 508FS 17
Fitting reducing windows (optional) 18
Air Outlet connection - 508DT only 19
Installation and Initial assembly (508FS only) 20
Counterweights 20
Castor option 21
Fitting the Castors 21
Fitting the rear stabilisers 22
Cooling fan option 23
Compressed air connection - 508FS only 25
Operating Procedures - Quick start guide 26
Introduction to the 508 control system - Operating buttons and icons 26
Initial Requirements (508DT &508FS) 28
Main Menu 29
508DT Basic operation 30
508DT Settings 31
508DT Saving Parameters to Memory 32
508DT Operating using saved parameters 32
508FS Basic Operation 33
Operating Procedures - Other settings / loading programs 35
508FS Fan system activation 35

Manual - Formech 508DT/FS - Rev 3
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Table Of Content
Optional extras 36
Tools 37
508DT/FS standard baseboard 38
508DT/FS reducing window baseboard 39
Plastics 40
Post Forming Operations 41
After forming 41
Trimming 41
Warranty 42
Seals 42
Heating elements 42
Vacuum system 42
Service / Repair 43
Replacing seals 43
Replacing a heating element 44
Electrical Troubleshooting 46
Vacuum / Pressure Troubleshooting (508DT & 508FS) 48
Cleaning 49
Lubrication 49
Electrical Wiring - 508DT 50
Vacuum Pump 2D351VM - 508DT only 51
Electrical Wiring - 508FS 53
Becker Pump VT 4.10 - 508FS Only 54
Pneumatics 508DT & 508FS 56
Major Parts Listing 508DT & 508FS 57
EC Certificate 59

Manual - Formech 508DT/FS - Rev 3
4
Safety
Thank you for choosing Formech. Please read and follow the below safety instructions
before attempting to install or operate your machine.
> Do not operate the machine until you have been trained and are fully conversant with it.
> Read and understand all of this user manual.
> This is a ‘single person operating’ machine.
> 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.
> 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 safety warning labels situated on the front and rear panels. Never remove any warning labels
from the machine.
> Note the ‘HOT SURFACES’ safety labelling on the heater & heater guard. These areas can become VERY
HOT.
> Only use the machine for vacuum forming plastic. It is not intended for any other purpose.
> 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.
> The heater and pump on this model are not intended to be left running indefinitely.
> 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.

Manual - Formech 508DT/FS - Rev 3
5
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 415Vac.
NEVER ATTEMPT 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 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 (508FS) 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.
HEALTH & SAFETY - Hazards specific to this machine.
5. Injury from Trapping.
There is a risk of trapping fingers 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 fingers or hands are not trapped.
Keep hands clear of the heater rails when pulling the heater forwards.

Manual - Formech 508DT/FS - Rev 3
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HEALTH & SAFETY - Hazards specific to this machine.
Safety
6. Lifting, Reaching and Stretching.
TAKE CARE WITH LIFTING REACHING AND STRETCHING WHEN PERFORMING THE FOLLOWING ACTIVITIES:
- Operating the manual heater, the loading of materials and unloading of plastic formings.
- Applying manual assistance to formings during vacuum.
- Drilling holes and trimming of mouldings on the machine after forming.
- The fitting and loading of mould tools.
- Loading and fitting 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.
7. 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 specification 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.
8. 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 fitted.
ENSURE THAT THE DUST, PARTICLES AND DEBRIS IN THE WORKING AREA ARE KEPT TO A MINIMUM.
ENSURE THAT SUITABLE EYE PROTECTION IS WORN.
9. Working at Height.
When installing the fan cooling system, 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.

Manual - Formech 508DT/FS - Rev 3
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HEALTH & SAFETY - Hazards specific to this machine.
Safety
10. 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 RELEASE TABLE AIR FUNCTION TO APPLY PRESSURE FOR ANY OTHER MEANS OTHER
THAN TO RELEASE THE MOULDING FROM A FITTED MOULD TOOL.
DO NOT BLOCK THE PUMP EXHAUST PORT ON THE REAR OF THE MACHINE AND DO NOT USE THIS
PRESSURE OUTLET TO APPLY PRESSURE FOR ANY OTHER PURPOSE.
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 AGAINST THE SIDES.
DO NOT USE THE FAN OUTPUTS TO APPLY AIRFLOW FOR ANY OTHER PURPOSE OTHER THAN THE
COOLING OF VACUUM FORMINGS AS PART OF THE VACUUM FORMING OR BLOW MOULDING PROCESS.
DO NOT USE THE FAN GANTRY TO HANG ANY ITEM.
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 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.
THE USE OF THIS MACHINE MUST BE ASSESSED, MONITORED AND CONTROLLED BY THE PERSON
RESPONSIBLE FOR THE HEALTH AND SAFETY IN THE ORGANISATION THAT OWNS AND OPERATES THIS
MACHINE.

Manual - Formech 508DT/FS - Rev 3
8
8
For Parts, Service & Technical Assistance
Telephone:[phone]
Fax: [phone]
508DT/FS
Installation, Operating and Service Manual
.
.
.
Desktop / Floor-Standing
Vacuum Forming
Machines
E C Machinery Directive
2006/42/EC
Declaration of conformity
We 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 Machine
Machine Function: Thermoforming of Plastic Sheet
Model / Type: 508DT/FS
Serial 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: A. Berry at address below.
…………………………………………………………………………………………………………
…………………………………………………………………………………………………………
Significant harmonised standards applied:
EN ISO 12100 : 2010
EN ISO13849-1:2006
EN 60204 –1 : 2006
EN 12409: 2008
______________________________________________________
Signed
Date: 15 October 2012
Name: Paul Vukovich
Position: Managing Director
Being the responsible person appointed by the manufacturer

User manual EC Certificate
of conformity
Your Formech Machine is supplied with:
Counter balance
weights (508FS)
Heater shed Table mesh
Power Cable - 508DT
C19 to BS 1363 Plug (UK & Ireland)
C19 to CEE 7/4 Plug -Schuko Plug (EU)
C19 to Nema 6/15 Plug (North America)
Power Cable - 508FS
2.5mm, 3 Core – 3m
+ Power lead (508DT)
Introduction

Manual - Formech 508DT/FS - Rev 3
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General Arrangement 508DT
720 607
680
1394
528
831
338
538
Machine footprint
(Dimensions are in mm)

Manual - Formech 508DT/FS - Rev 3
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General Arrangement 508DT
1 2
3 5
4 6
7
Electrical Specifications
220/240V, 13 amps, 50Hz single phase
208/220V, 13 amps, 60Hz two phases (North America)
Power consumption: 3,2 kW
Mechanical Specifications
Sheet size: 457 x 508mm
Forming area: 482 x 432mm
Max depth of draw: 185mm
Overall width: 720mm
Overall height: 538mm (1250mm with trolley)
Overall length: 1394mm (ASSEMBLED)
Weight: 100kg
Legend
1- Touch screen
2- Vacuum gauge
3- Clamp frame
4- Material clamp
5- Heater box
6- Table lever
7- Specification plate
Power inlet receptacle
Main fuse
Power switch ON/OFF
Air output
Transportation / Positioning
The 508DT will be supplied strapped to a Pallet or in a crate. The machine may unpacked and placed on a
bench, table or 508DT trolley. Lift the machine using the clamp handles at the front of the machine and the
rear rail lifting handle extensions. 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 move the machine. In
the case of the 508DT trolley, ensure that the 2 machine retaining screws are fitted to the under side of the
trolley / Machine. ALL MOVING AND LIFTING MUST BE SUPERVISED BY THE PERSON RESPONSIBLE FOR
HEALTH AND SAFETY.
Noise emissions
Noise emissions on the Formech 508DT are less than 70dB(A).
Machine storage
The Formech 508DT 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).

Manual - Formech 508DT/FS - Rev 3
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Machine footprint
(Dimensions are in mm)
General Arrangement 508FS
1474
681 757 720
1140
925
949

Manual - Formech 508DT/FS - Rev 3
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General Arrangement 508FS
Electrical Specifications
220/240V, 20 amps, 50Hz single phase
208/220V, 20 amps, 60Hz two phases
(North America)
Power consumption: 3,5 kW
Air supply requirement: 80PSI / 5 bar
Mechanical Specifications
Sheet size: 508 x 457mm
Forming area: 482 x 432mm
Max depth of draw: 290mm
Overall width: 720mm
Overall height: 1140mm (1950mm with cooling fan system)
Overall length: 1474mm (ASSEMBLED)
Weight: 100kg
Legend
1- Touch screen
2- Vacuum gauge
3- Clamp frame
4- Material clamp
5- Heater box
6- Table lever
7- Specification plate
Power inlet receptacle
Main fuse
Power switch ON/OFF
Air output
Transportation / Positioning
The 508FS will be supplied strapped to a Pallet or in a crate. The Machine may be carefully moved from
the transportation pallet and situated directly on a firm floor before installation. Ensure that the structure
and load bearing capacity of its position is sufficient for the machine weight. A minimum of 2 persons are
required to move the machine. Do not attempt to lift this machine without a mechanical aid. ALL MOVING
AND LIFTING MUST BE SUPERVISED BY THE PERSON RESPONSIBLE FOR HEALTH AND SAFETY.
Noise emissions
Noise emissions on the Formech 508FS are less than 70dB(A).
Machine storage
The Formech 508FS 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).
1 2
3 5
67

Manual - Formech 508DT/FS - Rev 3
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Machine arrangement
1. Touch screen.
Touch sensitive user screen to control the process with the ability to store programs in the memory.
2. Vacuum Gauge.
To indicate the vacuum level achieved during moulding.
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 black 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 self
adjusting.
5. Heater.
This carries the heating elements and is drawn forward by pulling the centrally mounted handle. If the
heaters are forward for more than 6 minutes after the timer has completed the heaters will switch off. If the
heaters are on the standby position (rear position) for more than 40 minutes then the heaters will switch off.
Contact Formech to change the default safety features.
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 allows you to supply other equipment that requires air pressure. Air is produced from
the exhaust of 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.
General Arrangement 508DT & 508FS

Manual - Formech 508DT/FS - Rev 3
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General Arrangement 508DT & 508FS
Machine arrangement (continuation)
7. Power connection.
508FS – supplied with 2.5mm cable fitted to connect to a single phase 20amp socket. See Safety section at
the beginning of this manual. 508DT – Supplied with C19 plug or C201 receptacle. Note the safety labelling.
7. Mains fuse.
This fuse protects the machine and should only be replaced by another of same type and rating. See Image
below – 508DT Only. 508FS – Circuit breakers are fitted to Live and neutral feeds internally.
7. Power Switch ON/OFF.
508DT - See Image below. When OFF, power is cut to all functions. Before commencing any repair work
always remove the mains lead from the Power Inlet Receptacle. 508FS – Supplied with a rotary 2 pole switch
on the electrical cabinet.
The fuse is positioned
separately above the power
socket. 508DT.

Manual - Formech 508DT/FS - Rev 3
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General Arrangement 508DT & 508FS
508DT Zoning
508FS Zoning
Front of machine Front of machine
200W
SQE
200W
SQE
200W
SQE
200W
SQE
200W
SQE
200W
SQE
125W
HSQ
125W
HSQ
250W
SQE
250W
SQE
250W
SQE
250W
SQE
150W FSQ
150W FSQ
150W FSQ
1 22
3
4
250W
SQE
250W
SQE
250W
SQE
250W
SQE
Heater Layout
Front of machine
250W
SQE
250W
SQE
150W
HSQ
150W
HSQ
300W
SQE
300W
SQE
300W
SQE
300W
SQE
200W FSQ
200W FSQ
200W FSQ
Front of machine
1 22
3
4

Manual - Formech 508DT/FS - Rev 3
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Installation and Inital assembly 508
Lifting and Handling - 508DT only
The machine is shipped with two lifting bars
fixed to the rear of the heater rails. Once the
machine has been positioned on either the
trolley or the table top, remove the lifting bars
before the heater guard can be fixed in place.
Remove the 2 screws on both sides
and remove the lifting bars.
Store the lifting bars for future use.

Slide the heater guard onto the
front rail link bars.

Manual - Formech 508DT/FS - Rev 3
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Installation and Inital assembly 508
Heater Guard - 508DT & 508FS
Slide the heater guard rails onto the front rail link bars
as shown. Take care to fit evenly so that the front and
rear rails meet and the fixing holes are aligned.
Fit the 4 screws – 2 each side – using an 8mm spanner.
Ensure all screws are tight and that heater rails are
aligned.
The heaters are kept in the front position for transit
by a screw that is positioned mid way along the front
heater rail.
Remove the screw from the side to allow the heaters to
be moved backwards.
1
2
3


Manual - Formech 508DT/FS - Rev 3
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Fitting reducing windows (optional)
Lift the clamp frame and
place the lower reducing
window in the machine.
Fit the bolt and the nut to
secure the window to the
clamp frame.
Do the same on the back of
the reducing window. Make
the nuts and bolts finger
tight. Do not use a spanner.
Reducing windows correctly
fitted to the machine.
Close and lock the clamp frame.
At this stage, you may have to
adjust the toggle clamps.
The lower reducing window
locates over the cap head
screws at the rear.
In order to locate the window,
position the plate holes 1cm
beyond the cap head screws
and pull back to locate.
Place the upper reducing
window in the clamp frame
at the rear.
Then locate it at the front of
the clamp frame.
Installation and Inital assembly 508

Manual - Formech 508DT/FS - Rev 3
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Air Outlet connection - 508DT only

Fitted with an 8mm tube Air outlet
connector for dome blowing.
Installation and Initial assembly 508

Manual - Formech 508DT/FS - Rev 3
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Installation and Initial assembly (508FS only)
Remove the nuts and washers from the counterweight
arms.
Lift the Counterweight arm with the screws and insert in
corresponding holes of the clamp frame.
Ensure the counterweight arm is fitted to the outside of the
clamp frame.
& Fit and tighten the washers and nuts removed in
Repeat for both sides of the clamp frame.
12
3
4
5
6
1
2
3
4 5 1
6
Counterweights