Formech 686 Service manual

1
686
Installation, Operating and Service Manual
.
.
.
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
7
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
8
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

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


Manual - Formech 686PT - Rev 8.8
11
General Arrangement
Electrical Specifications
220-240V, 3Wire, Single phase + Neutral + Earth, 50-60Hz.
208-220V, 3Wire, Twin Phase + Earth (Ground), 60Hz N. America. 380-415V, 5 wire, 3phase + Neutral +
Earth, 50-60Hz.
Power consumption: 8 kW
Mechanical Specifications
Sheet size: 686 x 660mm
Forming area: 646 x 620mm
Max depth of draw: 325mm
Max mould tool weight: 70Kg
Fan Power: 550W
Air Supply: 5 Bar, Dry & Filtered.
Overall width: 960mm
Length: 1932mm
Overall height: 1190mm
Overall height with cooling system: 2170mm
Weight: 260kg
Noise emissions
Noise emissions on the Formech 686PT are less than 70dB(A).
Machine storage
The Formech 686PT 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 moving
The Formech 686PT is prepared for transportation with the heater Locked forwards and the heater guard,
counterweights and accessories individually packed. All assemblies are supplied on a pallet or pallet crate
with the load centre of gravity approximately central.
Before lifting, remove all separate assemblies and leave the heater fixed in its position until located at its
operating site. Remove packaging where it assists with lifting and moving.
The machine may be lifted from either side taking particular care to avoid damage to the front clamping
frame and panels.
ENSURE THAT LOCAL LIFTING AND HANDLING PROCEDURES ARE APPLIED AND MONITORED BY
A PERSON RESPONSIBLE FOR HEALTH AND SAFETY.

Manual - Formech 686PT - Rev 8.8
12
Installation
The machine should be sited on a level concrete floor. 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 airflow to prevent overheating. During all
of the following installation ensure that the power supply is properly isolated.
Electrical connection
An 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 supply
Using 3 phases, Neutral and Earth connections STAR configuration. 3P, N & E
The major current consuming devices within this machine are 230V single phase. For 3 phase
machines each phase of a standard three phase supply should be connected to the L1 L2 & L3 of
the machine isolation switch. A neutral wire of full load capacity is required in this case. An Earth
stud is provided.
220-240 V Single phase supply
Using 1 phase, Neutral and earth connection – 1P, N & E
The major current consuming devices are 230V single phase. Machines are fitted with a 3 Pole
Isolator switch. Connect both Live & Neutral field feeder wires to the Switch terminations L1 ( Live),
L2 ( Neutral). An Earth stud is provided.
208-230 V Twin phase supply (North America)
Using 2 phases and earth connection – 2P & E
The major current consuming devices are 230V. Machines are fitted with a 3 Pole Isolator switch.
Connect both Live phases of the field feeder wires to the Switch terminations L1 & L2. An Earth stud
is provided.
Important notice on 3 phase & neutral connections
To prevent damage of components it is highly important to check that the three phase and neutral
connections are correct. The machine colors for wiring are as follows:
Brown L1 - Phase 1 Blue Neutral
Black L2 - Phase 2 Green/Yellow Earth or Ground
Grey L3 - Phase 3
After making connections to the isolator switch in the rear cabinet it is essential to verify that the
phases and neutral connections are terminated correctly. The three phases must be connected
to the connections L1, L2 & L3. The Blue neutral connections must be connected to the terminal
labelled N.
Verify these connections using a volt-meter / multi-meter by measuring the voltage potential
between the Neutral and each phase in turn. The voltage between each phase and the neutral
should measure 220 – 240V ac. Once this is confirmed the Electrical box cover may be fitted and the
isolator switch turned on.

Manual - Formech 686PT - Rev 8.8
13
Phase connections / Motor rotation
For all 3 Phase electrical connections the pump rotation direction is important. After switching the machine
on press the Vacuum button on the operation screen and check that vacuum is present at the hole in the
centre of the table. If there is no vacuum or if pressure is present then reverse 2 of the phase connections.
THIS MACHINE MUST BE PROPERLY EARTHED IN ACCORDANCE WITH LOCAL REGULATIONS.
Pneumatic connection
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 filtered. A competent
person must make compressed air connections.
If flexible hoses are used it is strongly advised that they are of Nylon, canvas or wire reinforced rubber and
suitably rated for pressure and temperature. Connection hose size is 12mm diameter. Threaded fittings are
BSP. The machine is supplied with 12mm Nylon Hose and an addition 12mm to ½” BSPT connector.
Maximum airline pressure must not exceed 5 BAR or 80 PSI.
Fitting of the heater guard
The Heater Guard is attached to the rear rails. Remove the 2 screws from each side of the heater rail
connecting links.
ENSURE THAT LOCAL LIFTING AND HANDLING PROCEDURES ARE APPLIED AND MONITORED BY
A PERSON RESPONSIBLE FOR HEALTH AND SAFETY.
Installation

Remove the transit lock
screw on both sides of
the heater.


Slide the heater guard onto the links
(2 people are required to perform this lift)
Refit and tighten the screws through the
rear heater rail and into the links.

Manual - Formech 686PT - Rev 8.8
14
Installation
Fitting of the stabiliser / Support arrangement

Back Panel View
Triangular support stabaliser
Remove 4off
M6 Cap head
screw - Fit
complete
stabaliser
assembly &
replace
screws
Remove the 2 screws on each side
of the lower rear back panel and fit
the bottom left and right support
triangles with the angle
returns facing inwards. See general
arrangement p.10, item 13.
Position the cross member support
plate between the 2 triangle
supports & fit the screws.
Ensure the 2 screws fitted under
the triangle and cross member are
touching the floor surface.
IT IS ESSENTIAL TO READ AND FULLY UNDERSTAND ALL THE INFORMATION IN THIS MANUAL
RELATING TO SAFETY AND THE SAFETY HAZARDS SPECIFIC 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.

Manual - Formech 686PT - Rev 8.8
15
Installation
Counterbalance arms and weights
The counterbalance arms attach to the clamp frame of the machine with the screws supplied. The two
counterbalance weights are normally supplied fitted to the arms and need to be set in position to balance
the clamp frame. They are easily adjusted by loosening the screw with a 13mm spanner or socket.
Adjustment is required if a reducing window is fitted. Adjust the weights so that the clamp frame is balanced.


COUNTERWEIGHTS ARE HEAVY ITEMS AND HENCE CARE MUST BE TAKEN TO PREVENT
TRAPPING OF FINGERS.
TAKE CARE WHEN ASSEMBLING, LOADING AND UNLOADING COUNTERWEIGHT. HEAVY ITEMS
CAN CAUSE CRUSHING IF MISSHANDLED, MISSUSED OR IF DROPPED.
WHEN LOADING AND UNLOADING COUNTERWEIGHTS ALWAYS ENSURE THE END STOP
LOCKING SPLIT PIN AND WASHER IS REPLACED AT THE END OF THE COUNTERWEIGHT ARM.
Fit the counterweight arm to the
outside of the clamp frame.
Fit the nuts and washers and en-
sure they are tightened fully.

Manual - Formech 686PT - Rev 8.8
16
Installation

A- Attaching the cooling system
1- Fit the gantry sides to the two heater rails at the boltholes on
either side of the moulding area with the four nuts and screws
supplied.
2- Fit the Gantry cross member to the top of the gantry sides
with the four nuts and bolts supplied. Mount the fan on the cross
member post so that the fan may be positioned behind the
cross member directing the fan draft forward and away from the
heater.
3- The swivel block is supplied fitted to the fan unit. Slide this onto
the cross member post and tighten the grub screws and locking
nuts. Never fit the fan posts on the underside of the cross member
as the fan may fall and cause injury. Mounting of the fans is a 2
person operation.
4- Adjust the fan unit to the required position and tighten all
the grub screws and lock nuts. Insert her cable into the clips on
the gantry and route the cable down to the fan socket on the
electrical box.
Optional - Cooling system
B- Operating the cooling system
The corresponding FAN button on the touch screen will operate the cooling fan at the appropriate time to
cool the moulding. The button changes colour when operated ON/OFF. It is worth considering the position
of the fan mounting to achieve good and consistent results with different mouldings.
Directing the airflow from behind the cross member down towards the centre of the moulding will reduce
the cooling effect of the fan on the heater.
Optional - Connecting the cooling bolster
The cooling Bolster is prefitted to the mould
table. PTFE water pipes are connected between
the underside of the bolster and the back panel.
Connect the feed and return pipes of the
temperature controlled water supply to the 2
fittings mounted on the rear of the machine.
Fitting are are 3/8” BSP.

Manual - Formech 686PT - Rev 8.8
17
Installation
Optional - Fitting the reducing windows
Hold the upper reducing window while bringing down the clamp frame (4&5). Fit the bolt and the nut on the
front and back to secure the window to the clamp frame (6). Dot not tighten with a spanner.
Adjust the counterbalance
weight with a 13mm spanner
sliding it to the rear of the ma-
chine (7).
Adjust the toggle clamps to
accomodate the extra thickness
of the reducing window (8).
12mm Baseboard in position
for tool mounting (9).
Lift the clamp frame and place the lower reducing window over the two cap head screws at the rear (1&2).
Place the upper reducing window in the clamp frame at the rear (3).
1 2 3
4 5 6
78 9

Manual - Formech 686PT - Rev 8.8
18
Installation
Optional - Vacuum Tank Configuration
The Vacuum Tank option comprises of a separate vacuum tank complete with fittings so that it can easily
be connected to the main body of the machine. Simply connect the vacuum tank hose to the main body
labelled port and fit the metal clip to retain the pipe.
An Oil pump is fitted to the machine internally that will continually remove air from the tank. When required
the vacuum valve connects both the tank and the pump to the mould tool table.
Optional - Heating Pyrometer
The heating pyrometer is mounted on the heater and further control equipment preconfigured at part of the
machine.
A pressure tank is supplied and mounted to the crossmember. Fit the rear crossmember with the pressure
tank mounted. The 4mm and 8mm pipes attached to the tank must be connected to the labelled push in
fittings on the rear of the machine. If the Heat Pyrometer option is supplied with the Vacuum Tank option
then the pyrometer pressure tank may be fitted on top of the vacuum tank using the fittings supplied.
Optional – Castors
Castors may be fitted to the 686 to allow the machine to be moved and relocated easily. If the machine
is supplied with the castor option then the two rear castors will be pre-mounted to the rear stabiliser
crossmember. The main frame of the machine will have 4 further castors. There are fixing points in each
corner. The mainframe castor must be fitted first.
The machine will be supplied on a pallet or crate. Move the machine so that the centre front of the machine
is at the corner of the pallet and the underside of the front two corners are accessible. The two locking
castors are fitted at the front of the machine by screwing in the M10 hex screw supplied to the fixing in the
base using a 17mm spanner. Ensure the castor fixings are tight.
Fit the rear standard castors with the fixings in the same way by moving the machine forwards again so that
the rear of the mainframe is supported by the corner of the pallet. When all fixings are tight, carefully move
the machine off the pallet and continue with the installation assembly.

Manual - Formech 686PT - Rev 8.8
19
Operation - Main Menu Functions
This section deals with the following:
• Touch screen arrangement & operation
• Heater controls and heater arrangement
• Operating the 686PT
• Other controls and user adjustments
Air System Initialisation when powering the machine ON
When the Machine is switched ON, the system requires initialization to supply air to the table cylinder
to prevent rapid movement due to depressurisation. Simply press the button on the HMI to initialize.
Touch Screen arrangement & operation
The main functions of the Formech 686PT are operated from the touch screen.
Main Menu
Allows entry to the Editing
Mode.
Allows entry to the Load Op-
tions Screen.
Enables the Heaters. Button
changes to Green when en-
abled.
Press
Load current settings:
This will load the most recently used set-
tings as shown in this box to the operating
screen.
Operate the machine manually:
This will load the default settings heater
settings only. Timers will count UP. The
time parameters used may be saved and
the heater power may be adjusted.
Load saved settings:
This will open the ‘load settings’ screen so
that previously saved parameters may be
loaded.
Press flag to select language

Manual - Formech 686PT - Rev 8.8
20
Operation - Manual Functions
Load save settings
Allows you to choose a Job already
saved in the memories available.
Press to skip to the next 10 me-
mory slots.
Select the memory Job required to
load the saved settings.
The main operation screen will load.
Main operation screen
This screen opens when a saved job is
selected giving access to the machine
function of the vacuum forming pro-
cess. (See page 21 below dealing with
Icon descriptions)
The arrow guides the user through
the main 5 machine functions of the
forming cycle. Remain on this screen
when performing continuous cycles.
This operating screen opens with the loaded timer settings and the job title shown in the centre of the
screen. On the heater timer button, there are 2 values. The lower value shows the actual heater time set for
this job memory. The top value is the COUNT DOWN timer showing how much time is remaining during the
heating cycle.
When this time reaches ZERO it will continue counting and show a negative value and indicate how much
extra heat time have been applied.
If the save function is pressed, the actual time used will be taken to the settings screen – this will include the
negative count. These and other settings can be edited and saved as the same or other title at memory slot.
The timer values stored in memory can be changed by accessing the settings screen using the settings but-
ton on the operation screen or the main screen.