Formech Compac Mini Service manual

11
Compac Mini
.
.
.
Installation, Operating and Service Manual
Desktop Vacuum
Forming Machine
For Parts, Service & Technical Assistance
Telephone: [phone]
Fax: [phone]

Manual - Formech Compac Mini
2
Table Of Content
Safety 3
Introduction and initial assembly 4
General Arrangement 5
Machine footprint 5
Electrical Specifications 6
Transportation / Positioning 6
Noise emissions 6
Machine storage 6
Mechanical Specifications 6
Machine arrangement 7
Reducing Windows (optional) 9
Operating Procedure 10
Operating Techniques 12
Optional Extras 13
Tools 14
Plastics 16
Post Forming Operations 17
After forming 17
Trimming 17
Warranty 18
Seals 18
Heating elements 18
Vacuum system 18
Service / Repair 19
Replacing seals 19
Replacing a heating element 20
Electrical troubleshooting 24
Vacuum / Pressure System 27
Cleaning 29
Lubrication 29
Spare Parts Listing 30
Wiring Diagram Formech Mini 31
Vacuum Pump D351VM 32
EC Machinery Directive 34

Manual - Formech Compac Mini
3
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.
> 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 en-
ter 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) pos-
sible 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.
Safety

Manual - Formech Compac Mini
4
Introduction and initial assembly
Your Formech machine is supplied with:
1x Electrical cable 1x Installation/Operations/Repair
Manual
1x EC Certificate of Conformity 1x Table Mesh
4
Compac Mini
.
.
.
Installation, Operating and Service Manual
Desktop Vacuum
Forming Machine
For Parts, Service & Technical Assistance
Telephone:[phone]
Fax: [phone]
EC 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 Lachinery Directive and the National Laws and regulations adopting this Directive
Modifictions 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: Compac Mini
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: Andrew Berry at address below
Significant harmonised standards applied:
EN ISO 12100 : 2010
EN ISO 13849 : 2006
EN 60204 - 1 : 2006
EN 12409: 2008
Signed:
Date:
Name: Paul Vukovich
Position: Managing Director
Being the responsible person appointed by the manufacturer

ENSURE THAT THE TABLE LEVER IS TIGHTLY SCREWED INTO THE CRANK MECHANISM ON THE
RIGHT HAND SIDE OF THE MACHINE. IF OPERATED WITH THE LEVER LOOSENED YOU MAY
DAMAGE THE CRANK OR THE HANDLE.

Manual - Formech Compac Mini
5
General Arrangement
Machine footprint
(Dimensions are in mm)
439.40
835
360 383
425
703
250
Power inlet socket

Manual - Formech Compac Mini
6
General Arrangement
1- Specification Plate
2- Power Inlet (EC)
3- Power Switch ON/OFF
4- Clamp Frame
5- Material Clamps
6- Heater Box
7- Vacuum / Pressure Valve
8- Table Lever
9- Digital timer
10- Vacuum Pump ON/OFF switch
11- Vacuum Gauge
Mechanical Specifications
Max Material Size: 305mm x 255mm
Max Forming Area: 280mm x 230mm
Max Depth of Draw: 125mm
Overall Width: 440mm
Overall Height: 425mm
Overall Length: 835mm
Weight: 35Kg
Electrical Specifications
Standard Voltage: 208V-240V ac
Frequency: 50-60Hz
Power: 1.1Kw
Compac Mini
7
8
9
10
6
11

6
2
1
4
5
3
Transportation / Positioning
The Compac Mini will be supplied strapped to a Pallet or in a crate. The machine may be unpacked and
placed on a bench, table or Compac Mini trolley. 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 Compac Mini trolley, ensure that the 2 machine retaining screws are fitted to the
under side of the trolley / Machine.
Noise emissions
Noise emissions on the Formech Compac Mini are less than 70dB(A).
Machine storage
The Formech Compac Mini 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 Compac Mini
7
General Arrangement
Machine arrangement
1. Specification Plate.
This states the essential machine data & CE marking.
2. Power Inlet receptacle.
The machine is supplied complete with a power cable that plugs into this receptacle and then into a suitable
power socket. If your machine is a special voltage or frequency then it may be supplied with a lead not termi-
nated into a mains plug. See Safety section at the beginning of this manual. Note the safety labelling.
3. Power Switch ON/OFF.
This is the main switch. When in the OFF position power is cut to all functions. Before commencing any re-
pair work always remove the mains lead from the Power Inlet Receptacle.
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 blue 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.
6. Heater Box.
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 this valve switches between removing air from between the mould and
moulding during forming (vacuum) and introducing air between the mould and moulding for finished part
release (pressure).
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 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.
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.

Manual - Formech Compac Mini
8
General Arrangement
Machine arrangement (continuation)
9. 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. 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.
10. Vacuum Pump ON/OFF switch.
This turns the 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. Vacuum Gauge.
This is situated on the top LHS 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 20”Hg / -680mbar of vacuum. If such levels
are not achieved check your mould / table configuration & clamp / plastic sealing.

Manual - Formech Compac Mini
9
General Arrangement
Reducing Windows (optional)
Reducing windows allow the use of smaller sheet material for smaller mouldings. To fit the reducing window:
1. Lift the clamp frame and place the lower
reducing window.
2. Locate the window against the clamp frame.
3. Place the upper reducing window in the clamp
frame at the rear.
4. Then locate it at the front of the clamp frame.
5. Fit the bolt and the nut to secure the window
to the clamp frame.
6. Reducing windows correctly fitted
to the machine.

Manual - Formech Compac Mini
10
Operating Procedure
Basic Operation
1. Press the power switch to ON. The digital timer
on the front panel will illuminate. It usually takes
between 10 and 15 minutes before the heaters
have reached their operating temperature.
2. With the heater fully back and the mould table
in the up position place your mould onto it.
3. Place the table into the lower position by
pushing the table lever away from you.
4. Position a sheet of plastic over the aperture.
The plastic should be placed over the white seals
around the aperture.
5. Pull the clamp frame down and close the mate-
rial clamps. Depending on the plastic thickness,
you may need to adjust the screws on the mate-
rial clamps to properly grip the plastic.
6. Set the timer down to zero using the ‘Down’
button to help you establish the time for the hea-
ting cycle. If you know the cycle time, then press
the ‘Up’ button to the right time.

Manual - Formech Compac Mini
11
Basic Operation (continuation)
Operating Procedure
7. Pull the heater forward over the plastic. As the
plastic heats up, it will begin to rise slightly. It will
then soften and begin to drop back.
8. Push the heater back slightly to test the softness
of the plastic. Be careful the plastic might be very
hot. Continue to heat until it is soft enough to form.
9. Turn on the vacuum pump and raise the table
until you can feel it lock into place. The plastic will
form around the mould tool.
10. Let the finished moulding cool down a little
before pulling the release valve downwards to
blow the part off the tool. Lower the table and
switch off the vacuum.
11. If the plastic is still too soft when you try to
release it, some distortion may occur. Make sure
the mould is not stuck in the moulding when
you lower the table.
12. Finally, release the material clamps to remove
the finished moulding.

Manual - Formech Compac Mini
12
Operating Techniques
Heaters
The powerful quartz heaters are designed to heat the plastic rapidly without burning the surface. The time
required to heat the plastic sheet remains fairly constant once the heaters have reached their operating
temperature.
Heating cycle times vary according to a number of factors. With a little experience, timings may be easily
estimated.
Some plastics such as styrene have a wide tolerance to heating times giving consistently good mouldings.
Care must be taken with other materials such as ABS, as the surface will blister if the temperature limit is
exceeded.
The moulding should be formed when the plastic is sufficiently relaxed to become indented by the blunt end
of a pencil but not soft enough to sag.
A properly heated sheet will give an excellently defined moulding. If the sheet is not hot enough while for-
ming the moulding will not pick up all the detail from the tool.
The times below were recorded using styrene at an ambient temperature of 20 degrees C
With the machine at operating temperature. Please note that these times are a guide only.
Various factors will affect the heating time including the colour and surface finish of the material.
1.5mm Thick = 60 seconds
2.0mm Thick = 95 seconds
4.0mm Thick = 240 seconds
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.

Manual - Formech Compac Mini
13
Optional Extras
1. Service kit 2. Reducing windows
3. Compac Mini trolley
The following items can be purchased for your Compac Mini vacuum forming machine:
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 conside-
red 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 a standard size of reducing windows: 5x4’’ or 125x100mm aperture. Formech can
also produce special size reducing windows. For more information please contact our sales department.
3. The Formech machine trolley allows you to easily move your Compac Mini machine. The 2 locking castors
assure the trolley remains in position all the time. Underneath there is also space to store plastic material
and moulds. The trolley dimensions are: depth: 760mm, height: 720mm, width: 460mm

Manual - Formech Compac Mini
14
Tools
All tools should be mounted on a baseboard. They should not have undercuts and must be produced with
slightly angular sides (‘draft angle’) to aid release. Vent holes are needed to allow the air to be evacuated
from pockets and sharp angles on the tool. Providing these holes are kept small (1mm diameter or less) they
will not leave marks on the surface of the finished moulding.
Tools made from wood or medium density fibreboard (MDF) are easily constructed and can give short runs
of good quality mouldings at a low cost (see notes page 16). The use of close-grained wood will avoid grain
patterns appearing on the mouldings.
Plaster of Paris may be used for one-offs but the plaster must be allowed to properly dry out. (See notes
below)
Aluminium tools have the advantages of carrying fine detail and being more resistant to both distortion and
surface damage. Aluminium tools should be pre-heated before use. A cool metal mould will absorb some of
the heat from the plastic sheet before it can take up the full definition.
Resin tools combine most of the advantages of metal moulds with relative ease of manufacture. Various resi-
nous materials are commercially available especially for vacuum forming tool production.
Repairs to the vacuum circuit can be costly. The use of talc as a release agent is not recommended.
It may clog the vacuum pump, valves and hoses.
MDF Baseboard
Aluminium Baseboard

Manual - Formech Compac Mini
15
Tools
NOTES:
Porous mould materials such as wood and plaster should be properly sealed to prevent the vacuum pump
from sucking out any moisture or sawdust, loose plaster etc. The vacuum circuit may quickly become blocked
with dust or slurry if moulds are not properly sealed.
As the plastic cools after forming it will contract, gripping the tool tightly. If the tool has been made with
sloping sides and has a good surface finish it will release more easily. Where the draft angle must be kept to
a minimum a release agent may be used to assist release.
Sealed moulds will usually release more easily. Silicon based release agents may be used on more difficult
moulds. Silicon based release agents are rapidly absorbed by porous (unsealed) moulds, rendering them
ineffective.
The baseboard can be made from either MDF or aluminium and needs to be 3.00 – 4.00mm (1/8”) thick.
The vacuum hole can be 19.00 – 20.00mm (3/4”) diameter and needs to be positioned 15mm forward of
the centre of the table.
19-20mm
15mm
The baseboard has to be 4mm shorter in
both directions than the forming aperture
of the machine e.g. Forming aperture
280mm x 230mm = baseboard size
276mm x 226mm.

Manual - Formech Compac Mini
16
Plastics
Plastic sheet is commercially available in a wide variety of grades, thickness and colours. Materials such as
styrene and PVC are most suited to vacuum forming. Other materials such as acrylic, polypropylene and
polycarbonate will mould but difficulties may be encountered.
It is not within the scope of this manual to attempt to list all the potential problems and their solutions. It is
recommended that the newcomer to vacuum forming gains experience and confidence with easily formed
materials before moving onto the more difficult materials.
Formech has available a Vacuum Forming Guide which will cover some of these topics in more details. Please
contact Formech to gain access to this guide.

Manual - Formech Compac Mini
17
After forming
After forming, most plastics can be subsequently heat formed to add such details as folds or clips. Although
many plastics can be printed, and in some cases painted, the presence of release agent used to help free a
tight moulding may make the surface resistant to further decoration.
Trimming
An ideal moulding will be ready for use when removed from the machine and requires no finishing. However,
most mouldings do require trimming before they can be used.
There are numerous methods available for this process.
Thin materials can be trimmed with a sharp knife. Shaped cutting dies can be used to cut out intricate
shapes. If no flange is required on the finished product then a trimming saw mounted in a pillar drill will cut
the moulding in a horizontal plane to free it from the surrounding material.
In mass production environments the range of equipment available for this requirement encompasses
clicking presses, roller presses, routers, horizontal band saws, water jet cutters, laser cutters and many others.
Formech has available a Vacuum Forming Guide which will cover some of these topics in more details. Please
contact Formech to gain access to this guide.
Post Forming Operations

Manual - Formech Compac Mini
18
Warranty
Reliability and a long service life are synonymous with the Formech brand. However, as with any machinery,
certain parts will require periodic replacement.
Seals
The silicon seals applied to the mould table and to the top aperture of the machine (clamp) are seen as
being consumable parts, their service life will depend on how the machine is treated and how often it is used.
The table and clamp seals are not covered by our warranty.
Heating elements
The Quartz infrared heating elements supplied with this machine are manufactured using quartz tube and
therefore may break or crack with impact or physical shock.
The Quartz heating elements contain internal filaments, which become extremely hot when power is applied.
The wire expands and contracts as it heats and cools.
Eventually, due to the continual expansion and contraction, the wire will fracture and a new element will be
needed. This may take 10 years or more. Because of this we are unable to apply our standard warranty to
Quartz heating elements. However our experience is that this form of infrared heating is durable, reliable and
more resilient to shock and impact than similar ceramic products
The heating elements are not covered by our warranty.
Vacuum system
The vacuum system on this machine is fairly simple but uses high quality components throughout. The life
expectancy of the vacuum system will be compromised by the ingress of dirt, shavings, dust, liquid etc.
THE VACUUM CIRCUIT INCLUDING THE VACUUM PUMP WILL NOT BE COVERED BY OUR WARRANTY IF
THEY ARE FOUND TO BE BLOCKED WITH FOREIGN MATTER OR CORRODED BY THE INGRESS OF LIQUID.

Manual - Formech Compac Mini
19
Replacing seals
Clean up completely,
mask the area and ‘key’
the surface.
Apply the sealant
evently.
Fit overlapping silicone
strips and ‘bed’ into
sealant.
Apply a 45 degree mitre
at the corners. Ensure
the joint is sealed.
12
3 4
1. Remove all the existing seal and adhesive with a sharp blade. Mask off the sealing area with masking tape
or similar (Mask the outside for top frames or reducing windows & the inside for table seals). Prepare the
sealing area with emery cloth or similar to achieve a good surface for the new adhesive to key with. Ensure
that the surface is clean from dust, dirt and grease.
2. Apply a generous bead of high modulus silicone sealant to the masked area and smooth down to give a
consistent layer.
3. Cut the silicone strip in lengths long enough to overlap the corners. Do not stretch the seal strip when
measuring or applying. Lay each strip on to the seal area overlapping at the corners. Ensure the seal strip is
bedded down well by pressing firmly along the full length.
4. With a sharp blade cut a 45° mitre joint at all corners. Fill gaps in the joints with sealant. Remove the
masking tape before the sealant has set. For best performance leave seal to set overnight.
Service / Repair

Manual - Formech Compac Mini
20
Service / Repair
Replacing a heating element
1- Unplug the machine from the
mains. Bring the heater completely
forward and remove the fours screws
retaining the cover.
2- Remove the cover on top of the heater.
Before any maintenance work is carried out, electrical supply must be locked in the OFF position
or the mains lead removed.
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 res-
tored.
If the plastic is not being heated evenly and there is an obvious cold spot then follow the below
procedure.
> Switch off machine and let heater cool completely, this will take at least 15 minutes.
> Bring the heater half way forward, place hand near but not on elements
to see if they are still hot. If they are, let machine cool for a further 15 minutes.
> When elements are completely cool, turn on machine and feel each element individually.
The difference in temperature will quickly become noticeable. If one or more elements fail to heat
then follow below.