Formech 686 Service manual

1
686
Installation, Operating and Service Manual
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For Parts, Service & Technical Assistance
Telephone: [phone]
Fax: [phone]
Rev 8.8
Floor Standing Vacuum
Forming Machine

Manual - Formech 686PT - Rev 8.8
2
Table Of Content
Safety 4
Introduction 8
General Arrangement 9
Machine footprint 9
Electrical Specifications 11
Mechanical Specifications 11
Noise emissions 11
Machine storage 11
Machine transportation, lifting and moving 11
Installation 12
Electrical connection 12
Phase connections / Motor rotation 13
Pneumatic connection 13
Fitting of the heater guard 13
Fitting of the stabiliser / Support arrangement 14
Counterbalance arms and weights 15
Optional - Cooling system 16
Optional - Connecting the cooling bolster 16
Optional - Fitting the reducing windows 17
Optional - Vacuum Tank Configuration 18
Optional - Heating Pyrometer 18
Optional - Castors 18
Operation - Main Menu Functions 19
Operation - Manual Functions 20
Load save settings 20
Main operation screen 20
Icons descriptions 21
Language options 22
The help function 22
Mould table drive 22
Basic operation using default settings 23
Manual operation screen 23
The vacuum forming process 24
Operation - Settings 25
Memory settings 25
Select the memory slot 25
Function settings 25
Heater zone settings 26
Heater standby settings 26
Heater settings 26
Save settings 27
Default heater settings 27

Manual - Formech 686PT - Rev 8.8
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Table Of Content
Operation - Options 28
Vacuum Tank Option 28
Bolster Option - fixing tooling 28
Heating Pyrometer Option 29
Operation - Heater Settings 30
Heater controls & heater arrangement 30
Heating zone control and adjustment 30
Operation - Other Controls and User Adjustments 31
Table speed adjustment 31
Clamp frame rear spring adjustment 31
Clamp frame front clamp adjustment 31
Counterweight adjustment, loading & unloading 32
Tools 33
Plastics 36
Post Forming Operations 37
After forming 37
Trimming 37
Warranty 38
Clamp seals 38
Heating elements 38
Vacuum system 38
Fault Diagnostics / Maintenance 39
Electrical troubleshooting 39
Heater 40
Replacing a heating element 41
Auto-levelling system 44
Vacuum 45
Vacuum system 45
Pneumatics 46
Table cylinder maintenance 47
Clamp & table seals 47
To replace a damaged or worn seal 48
Panel seals 49
Cleaning 49
Lubrication 49
Electrical Circuit Information 50
Becker Pump VT 4.16 65
EC Certificate 67

Manual - Formech 686PT - Rev 8.8
4
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 qualified 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 filtered & 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 finished product and any
waste.
11) This machine is fitted with a dry running vacuum pump. Do not lubricate. Do not allow any liquid to enter
the vacuum system. Severe damage may be caused if the above is not observed.

Manual - Formech 686PT - Rev 8.8
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 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 80PSI 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 2 HANDED CONTROL SYSTEM.
HEALTH & SAFETY - Hazards specific to this machine

Manual - Formech 686PT - Rev 8.8
6
HEALTH & SAFETY - Hazards specific to this machine
Safety
6. 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.
7. 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.
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 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.
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 fitted.
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, 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 686PT - Rev 8.8
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HEALTH & SAFETY - Hazards specific to this machine
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 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 ALLOW OTHER PERSONS WITHIN 1 METRE (39 INCHES) OF THE TABLE / APERTURE TRAP POINT
WHEN OPERATING THE TABLE USING THE TWO HANDED CONTROL TABLE LIFT FUNCTION.
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 UNDERSIDE OF THE REAR OF THE MACHINE TO STORE ANY ITEM(S).
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 MOUNT THE FAN POSTS ON THE UNDER SIDE OF THE FAN GANTRY.
DO NOT OBSTRUCT THE HEATER TRANSORT WITH ANY ITEM OR USE THE TRANSPORT WHEELS TO CUT
OR FORM ANY ITEM OR MATERIAL.
DO NOT USE ANY OTHER PART OF THE HEATER TO MOVE THE HEATER FORWARDS AND BACKWARDS
OTHER THAN THE HEATER HANDLE.
DO NOT REMOVE THE SIDE PANELS OF THIS MACHINE TO USE THE PNEUMATIC CYLINDER TO CUT,
COMPRESS, BEND OR FORM ANY ITEM.
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.

Manual - Formech 686PT - Rev 8.8
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Introduction
The Formech 686PT is a highly versatile, manually operated Vacuum Forming Machine that will produce high
definition mouldings in up to 6mm thick material. These machines are intended for use only for the vacuum
forming of plastics components and for the blow moulding of heated plastics. The 686PT is ideal for proto-
type development work whilst also quite capable of small and large production runs.
The Formech 686PT incorporate the following features:
• Reliable and robust PLC control system and easy to use graphical touch screen with single
screen forming cycle operation and 20 memory storage facility.
• Powerful quartz heaters PLC controlled in 6 heating zones.
• Heater power level standby feature allowing energy saving when heater is in rear position.
• Heater safety shutoff after idle period.
• A powerful filtered dry rotary vane vacuum pump.
• Vacuum gauge indication.
• Auto sheet levelling system – AUTO-LEVEL feature.
• AUTO-VACUUM function - triggers the Vacuum when raising the mould table.
• A pneumatically powered mould table incorporating 2 handed manual control allowing easy
and safe use of heavy mould with adjustable table speed.
• A powerful compressed air blow facility to release the moulding from the tool.
• The machine has been designed to be highly adaptable and functions such as changing a
mould, or fitting reducing windows (which allow smaller sheets to be used) can be carried out in
the minimum amount of time.
• Optional powerful fan cooling system.
• Optional reel feed system.
• Optional heating pyrometer
• Optional vacuum flow regulator
• Optional castor
• Optional cooling bolster.
• Optional vacuum tank configuration.
This manual is the original user instructions for the Formech 686PT. It informs the user on machine safety,
assembly, operation and maintenance. A more comprehensive guide to the vacuum forming process is avai-
lable from Formech.

Manual - Formech 686PT - Rev 8.8
9
General Arrangement
1932
960 846
1157
1165
948
Machine footprint
(Dimensions are in mm)
1190

Manual - Formech 686PT - Rev 8.8
10
General Arrangement
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5
4 6
2
3
71
1- Heater
2- Clamp Frame Handle
3- Toggle Clamps
4- Mitsubishi touch screen
5- ‘Table Up’ Control Buttons
6- Vacuum Gauge
7- Heater Handle
8- Heater Transit Lock
9- Heater Guard
10- Counter Balance Weights
11- Self-adjusting Clamps Springs
12- Control Box with Main Switch
13- Heater Rear Supports
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