Formech FM660 Service manual

MODEL: FM660 (manual power table and clinica version)
Single Heater Vacuum Forming Machine
Installation
Operating and Service Manual
For Parts, Service & Technical Assistance
Telephone
+ 44 (0) 1582 46 97 97
Fax
+ 44 (0) 1582 46 96 46
Email
[e-mail]

2
Index
Safety...........................................................................................................................................3
Introduction.................................................................................................................................5
General Arrangement.................................................................................................................6
Initial Assembly ..........................................................................................................................7
Electrical connection..............................................................................................................7
Pneumatic connection............................................................................................................7
Attaching the stabiliser bar arrangement.............................................................................7
Heat Guard assembly and fitting...........................................................................................7
660 Heater - no fitting required..............................................................................................7
Initial Assembly ..........................................................................................................................8
Counterbalance arms and weights .......................................................................................8
Optional Cooling System.......................................................................................................8
Operating Procedure..................................................................................................................9
Control panel general arrangement and use...........................................................................9
Operating Procedure................................................................................................................10
Operating Techniques..............................................................................................................11
Heaters...................................................................................................................................11
Heater timer...........................................................................................................................12
Bubble moulding...................................................................................................................12
Tools..........................................................................................................................................13
Plastics......................................................................................................................................14
Post Forming Operations ........................................................................................................14
After forming .........................................................................................................................14
Trimming................................................................................................................................14
Forming Difficulties..................................................................................................................15
Warranty....................................................................................................................................17
Heating elements ..................................................................................................................17
Vacuum system.....................................................................................................................17
Service\Repair...........................................................................................................................18
Electrical................................................................................................................................18
Heater.....................................................................................................................................18
Replacing a heating element ...............................................................................................18
Auto-levelling system...........................................................................................................19
Vacuum (660 Clinica version filtering system)..................................................................20
Vacuum / pressure system ..................................................................................................21
Pneumatics............................................................................................................................21
Clamp & table seals..............................................................................................................23
To replace a damaged or worn seal....................................................................................23
Panel seals ............................................................................................................................23
Electrical wiring diagram.........................................................................................................25
Heater wiring diagram..............................................................................................................26

3
Safety Formech FM660
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 IEE
regulations and carried out by a suitably qualified technician. THIS MACHINE MUST BE EARTHED
IN ACCORDANCE WITH LOCAL REGULATIONS.
2) Ensure that where a pneumatic supply is required it is regulated to 6 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 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 scrap.
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.

4
Safety Formech FM660
HEALTH & SAFETY.
Hazards specific to this machine.
It is vital that any person using this machine is made fully aware of the potential dangers that
could arise from incorrect use.
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.
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
3. Injury from compressed air.Pressures up to 100 PSI will be present in large volumes on this
machine. 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.
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 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.

5
Introduction Formech FM660
The Formech FM660 is a compact, manually operated Vacuum Forming Machine that will produce high
definition mouldings in up to 6mm thick material.
The Formech FM660 incorporates powerful infrared ceramic heaters, which are thermostatically
controlled in concentric zones.
A powerful reverse-blow facility to release the moulding from the tool is integrated into the FM660.
The machine is fitted with an auto-level facility, which detects a droop in the sheet of plastic resulting
from softening during its heat cycle. Air is then blown into the chamber beneath the plastic keeping the
sheet level until it is ready to be formed.
A countdown timer is fitted as standard.
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.
The powered table version of this machine allows easy and safe use of heavy moulds.
The FM660 is ideal for prototype development work whilst also quite capable of small and large
production runs.
This manual informs the user on machine assembly, operation and service. It also provides an
introduction into vacuum forming with some useful advise on mould making and post forming
processes. If you would like a more comprehensive guide to the vacuum forming process then please
visit the support section of the Formech web page. A Training Manual is provided in a download and
printable format.

6
General Arrangement Formech FM660
Features
1 Material clamp 6 Drape table lever
2 Heater movement handle 7 Electrical Box & Main Switch
3 Heater safety guard 8 Vacuum filter
4 Heater zone controller and neon 9 Stabiliser attachment
5 Control panel
Mechanical specifications Electrical specification
Material size 660mm x 660mm Standard voltage 220/240V S/ Phase
Forming area 620mm x 620mm 380/415V 3/ Phase
Depth of draw 400mm Standard frequency 50/60Hz
Mat. thickness 6.0mm max. Standard max Power 7550W
Overall height 1280mm
Overall depth 1900mm Pneumatic specification
Overall width 940mm
Weight 260Kgs Compressed air-80PSI / 6 bar
Optional extras
550W cooling fan system
Pneumatic table (Depth of draw, 300mm)
Reducing windows –450mm x 450mm / 300mm x 300mm / 150mm x 150mm
Reel feed gantry
Primary Particle Filter with Drain.
O
N
O
F
F
Form ec
h
FM 660
1
2
346
5
7
8
9

7
Initial Assembly Formech FM660
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 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.
415V Three phase supply.
The major current consuming devices within this machine are 230V single phase. However, in order to
balance the load to electricity generator's requirements, each phase of a standard three phase supply
should be connected to the L1 L2 & L3 of the machine. A neutral wire of full load capacity is required in
this case.
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.
All fittings are threaded BSP. If flexible hoses are used it is strongly advised that they are of canvas or
wire reinforced rubber and suitably rated for pressure and temperature. Connection hose size should
be 12mm diameter.
Maximum airline pressure must not exceed 6BAR or 80 PSI
Attaching the stabiliser bar arrangement
The kit comprises two sidepieces, one stabiliser bar and fixing screws.
1Remove the two lower screws from each side of the rear panel.
2Align stabiliser side piece with the panel holes.
3Insert screws. Do not tighten at this stage.
4Place stabiliser bar between the side pieces aligning with the screw holes and insert screws.
5Ensure the stabiliser assy is situated at its lowest point of adjustment and tighten up all screws.
Heat Guard assembly and fitting
The Heater Guard is attached to the rear rails and heat shield. The rails slot together with the rail key
bar. Remove the screws fitted to the rear of the front rails and slide the complete heater guard into
place. Refit the two M6 screws and nuts into the rail key and rear rail, one on each side. Ensure that
these fixing are tight and that the rails are aligned.
660 Heater - no fitting required.
The heater is attached to the machine with the heater wheels sitting on the rails. The heater is
connected to the electrical box located at the rear of the machine with cable and chain and electrical
conduit. Remove any transit ties after fitting the Heater guard and rear rails. The heater should roll
freely back into the heater guard.
Drape Table lever
This lever may require fitting. Remove the bolt from the main crank on the right hand side of the
machine. Place the bolt in the main shaft of the lever and push the keyed shaft into the keyed main
crank. Tighten the shaft bolt well. It is important that this retaining bolt remains tight, check regularly.

8
Initial Assembly Formech FM660
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 grub screw. Ensure that the end
stops are always in place.
Adjustment is required if, for example, a reducing window is fitted.
Optional Cooling System
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 gantry sides with the four nuts and bolts supplied. The fan
mounting post should be attached to the cross member so that the fan can be positioned behind
the cross member directing the fan draft forward away from the heater.
3 The swivel block should be 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.
4 Adjust the fan unit to the required position, tighten all the grub screws and lock nuts.
Using the Cooling System
The corresponding ON / OFF buttons on the control panel can operate the cooling fan at the
appropriate time to cool the moulding. It is worth considering the position of the fan mounting to
achieve good and consistent results.
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.

9
Operating Procedure Formech FM660
Control panel general arrangement and use.
The FM660 / FM660PT is operated from the control panel. The various buttons are labelled as above.
Unlike conventional push button systems, the FM660 control panel is flush with touch sensitive buttons.
Simply touch the button. No force is required. These buttons have no moving parts.
The following is a brief description of the operation of the buttons to be referred to in conjunction with
the operating procedures on the next page.
Auto-level
This operation will latch the pump ‘on’ and monitor the beam sensor. The pump pressure valve will turn
on when the beam is broken. Pressing any sequence button will unlatch this function.
Pre-stretch
This operation will turn on the compressed air valve to allow air to flow into the sealed cabinet. This
function does not latch.
Mould
This operation will latch the pump and the vacuum valve on to apply vacuum to the table hole. Pressing
any sequence button will unlatch this function.
Cooling Fan
There is an ‘ON’ and an ‘OFF’ button for this function. No other buttons will affect the fan operation
Release
This operation will turn on the pump and the pressure valve together. This function does not latch.
Stop
This button will stop any latched function and return the system to standby.
Timer
This has a 999 second digital display countdown timer. The up and down buttons adjust the set time,
holding these button will speed up the adjustment. Set to zero to disable the timer. Countdown will
start when the heater is moved to the forward position.
Table Up (FM660PT only)
These two buttons must be touched simultaneously and held to allow the table to be driven up.
Removing either hand during the command will stop the table movement.
Table down (FM660PT only)
This button will drive the table down when held. The command will stop if not held.
Table Up Table Up
TableDown STOP Cooling Fan
ON OFF
Timer Auto-Level Pre-stretch Mould Release
STOP
Cooling Fan
ON OFF
Timer Auto-Level Pre-stretch Mould Release
FM660
FM660PT

10
Operating Procedure Formech FM660
Turn the isolator switch situated on the electrical box on the rear of the machine to the ‘ON’
position.
Using the heater controls, turn the zones on to provide power to the heaters. It usually takes
between 15 and 20 minutes before the heaters have reached their operating temperature.
Place your mould onto the drape table. See the section dealing with mould design to ensure
that your mould is suitable. Place the table into the lower position by pushing the table lever (6)
away from you.
Open the material clamps (1) and raise the clamp frame. Position a sheet of plastic over the
aperture. See the section dealing with plastics to ensure that your material is suitable.
Pull the clamp frame down and close the material clamps. The plastic should completely cover
the white seals around the aperture. Use the adjusting screws at the front of the material
clamps to properly grip the plastic. The rear of the clamp is spring loaded. The pre-load spring
tension can be adjusted by moving the position of the two lock nuts.
After the heater has reached operating temperature, pull it forward over the plastic using the
handle at the front of the heater unit.
Activate the auto-level by touching the blue button. This enables the auto-level feature. If the
plastic is sagging and not being heated evenly then the auto-level feature may be used to keep
the plastic level while the heater is forward and until ready to form a mould.
As the plastic heats up it may begin to rise slightly. It will then soften and begin to drop back.
If the heating cycle time is known then the timer can be set prior to bringing the heater forward.
If not using the timer push the heater back slightly to test the softness of the plastic manually or
to observe its state. Continue heating until it is soft enough to form. At this point, push back the
heater all the way.
Touch the white pre-stretch button to inflate the plastic before moulding if required. This feature
is particularly useful if the mould is high because it keeps the plastic at a more even thickness
throughout the moulding. Pre-stretch may also be used as the table is rising to keep the bubble
inflated. If the moulding is quite high it may be necessary to pre-stretch the plastic before
moulding takes place.
Press the green ‘Mould’ button and lift the mould table by pulling back the drape table lever until
the crank locks in place and the drape table is fully raised.
The green mould button is used to apply vacuum to the table. The moulding will form around
the tooling.
For the powered table option the table is raised by touching both the two red ‘Table Up’ buttons
simultaneously (this must be performed with both hands and held until the table is fully up).
At the appropriate time the fans may be turned on to start the plastic cooling process –touch
the white ‘ON’ button. When the moulding is cooled, touch the white ‘OFF’ button.
Once the plastic has cooled sufficiently the yellow release button may be pressed to blow the
moulding off of the mould. Too long or too soon a release may distort the moulding.
Once released the moulding is now complete and the table may be lowered using the drape
table lever and the clamp frame unclamped. To lower the powered table touch the ‘Table Down’
button, holding this until the table has reached its lower position.

11
Operating Techniques Formech FM660
Heaters
The powerful infrared ceramic 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.
The movement of the heater is manually controlled. The operator is able to send the heater partially
back to check the condition of the plastic and then bring it forward to continue the heating process. This
action will not interrupt and restart a timed heating cycle unless the time has elapsed and the alarm
already sounded. Always use the red handle to move the heater.
The heater control system uses 'simmerstats' to vary the output of individual zones as displayed on the
heater front panel. There are six controllable heating zones, three concentric zones, the outer zone is
split into four zones to enable users to balance the heating and allow for sides drafts etc.
After the required zone heat level, as set on each simmerstat, has been reached, the corresponding red
neon indicator will go off. This indicates that the zone is not drawing any power. As the elements cool
down the power cuts back in and reheats the zone.
The individual zones may be set up to provide an even spread of heat. To achieve the best results set
the inner zones lower than the outer zones and remember that the rear of the heater will always run
hotter than the front. Having set the heaters, slight adjustments may have to be made depending on the
mould design, plastic type / thickness / colour and the machine & environment temperature / conditions.
When using the full forming area it is advisable to keep the central zones 1 and 2 turned down slightly.
These areas retain the heat the most and the outer zones lose the heat the fastest. When using
reducing frames the zones not in use should be turned down. Always push heaters over rear heat
shield when not heating plastic.
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 materials, which are Hygroscopic (retain
moisture) such as ABS, as the surface will blister if the material has not been pre-dried.
The moulding should be formed when the plastic is sufficiently ‘relaxed’ or at its ‘plastic transition’
temperature. A properly heated sheet will give an excellently defined moulding. If the sheet is not hot
enough while forming 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°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 = 45 seconds
2.0mm Thick = 95 seconds
4.0mm Thick = 170 seconds

12
Operating Techniques Formech FM660
Heater timer
The FM660 is fitted with a three digit LED count down heater timer intended to assist the production of
a large number of similar mouldings.
The timer function is enabled when a number is shown in the display and disabled when the display
shows ’Zero’. The timing ‘seconds’ value is adjusted by touching the ‘’ or ‘’ buttons either side of the
three digit display. The adjustment count will speed up if you hold your finger on the up/down
adjustment buttons.
The timer countdown is triggered when the heater reaches its forward position and visibly counts down
the seconds to give a useful indication of the heat time remaining.
An audible bleep is given when the countdown is complete and the display resets to the pre-set time.
The buzzer indicates that the heating cycle is complete and the heater may be pushed back.
Pushing the heater partially backward or forward during the heating cycle will not interrupt the
countdown.
Bubble moulding
With the FM660/FM660PT it is possible to produce bubble mouldings without using a tool. To form a
bubble the plastic sheet should be heated with the drape table in the lowered position. When the plastic
sheet has heated right through, push back the heater, touch the pre-stretch button and hold. If you are
using the FM660 without an air supply use the release button to blow. The plastic will start to inflate.

13
Tools Formech FM660
Tools for vacuum forming should always be solidly constructed as the operating air pressure reaches
approximately 100 kg over an area 100mm x 100mm (one ton per square foot)
All tools should be mounted on a baseboard. They cannot 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 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 note below)
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 note below)
Metal tools have the advantages of carrying fine detail and being more resistant to both distortion and
surface damage. Metal 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 resinous materials are commercially available especially for vacuum forming tool production.
NOTE: 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 choked with dust or slurry if moulds are not properly sealed.
Repairs to the vacuum circuit can be costly. A drain filter option is available and strongly
recommended if forming plaster moulds. The vacuum filter is not designed to prevent moisture
getting into the vacuum pump.
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 use of talc as a release agent is not recommended. It may clog the vacuum circuit.

14
Plastics Formech FM660
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.
Post Forming Operations Formech FM660
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. Trim or Spindle saw are
available from Formech. Please contact our sales department for further information.
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.

15
Forming Difficulties Formech FM660
The purpose of the following section is to help the user in overcoming some problems frequently
encountered in thermoforming. Please remember that the majority of thermoforming faults are caused
by incorrect machine setting or poor mould design.
This section is a guide only and cannot impart the practical experience and skill that any user will
eventually attain. You can find a more comprehensive trouble-shooting guide in the Formech training
Manual located in the support section of the Formech web page. www.formech.com
PROBLEM
CAUSE
REMEDY
Lack of definition
Material too cold
Increase heating time/temp.
Mould too cold
Warm mould
Insufficient vacuum
Adjust vacuum timings
Check vent holes on mould
Is mould restricting vacuum flow? Are
vacuum tracks in mould adequate?
Webbing (small pleats at
corners of mouldings)
Incorrect pre-stretch
height
Adjust pre-stretch flow and/or time. Check
panels for leaks
Incorrect heater zoning
Adjust problem zones
Material overheated
Reduce heating time
Vacuum speed too fast
Regulate to suit
Mould design/position
Increase tapers or radii. Use plug assist.
Move cavities further apart (Multiple
moulds)
Webbing
Excess material
Reduce material size or use 'dummy'
moulds
Shrinkage of moulding
(after removal from mould)
Product removed from
mould too quickly
Increase timings to allow longer mould
contact
Increase cooling time
Moulding too thin in areas
Incorrect heater zoning
Decrease temperature in problem zones
Too much pre-stretch
Decrease flow or timing
Cold spots
Check elements are working. Are there
any draughts?
Mould too cold
Warm mould
Material not consistent
Consult supplier

16
Forming Difficulties Formech FM660
PROBLEM
CAUSE
REMEDY
Creased or distorted formings
Excessive mould release
pressure or timing
Adjust to suit
Material too hot at release
Increase cooling time
Material thinning
Adjust heater zoning
Thick tops on finished
mouldings. (Chill marks)
Mould too cold causing rapid
cooling on contact
Increase mould temperature.
Adjust flow on water cooled moulds
Design of mould
Use plug tool to assist material flow
Insufficient pre-stretch
Increase pressure, flow or time
Material too hot or too cold
Increase heating time/temp.
Marks on finished mouldings
Damaged or dirty mould
Repair or clean mould. Use
blowgun between formings.

17
Warranty Formech FM660
Reliability and a long service life are synonymous with the Formech brand. However, as with any
machinery, certain parts will require periodic replacement and regular maintenance and care will
prolong machinery life.
Clamp 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 infrared heating elements supplied with this machine are manufactured from a ceramic material
and are very brittle. A shock to the machine may break an element.
The heating elements contain a length of resistance wire internally, which becomes extremely hot when
electricity 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 a decade or more. Alternatively it could happen as a result of an impact or
shock. Because of this we are unable to apply our standard warranty to ceramic heating elements.
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.

18
Service\Repair Formech FM660
Apart from the table and clamp seals, which are considered to be consumable items, it is unlikely that
you will need to service or repair your machine for many years. This is providing that you have noted
the sections regarding the vacuum system and heating elements.
Electrical
Before any maintenance work is carried out both electrical and air supplies must be locked in
the OFF position. 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.
Faults on circuit boards are rare but loose plugs and terminals are responsible for most electrically
based failures. A logical approach to detecting the fault begins with an exact appraisal of the fault
scenario.
Much time can be wasted looking in the wrong areas for a problem that, when found, was obvious.
Heater
The flexible conduits between the heaters and the control cabinet contain a number of heatproof power
(and in some cases thermocouple) cables. Due to the continual motion of the heater these will
eventually suffer from fatigue and require replacement.
Only the correct grade of cable should be used, and the work carried out by a skilled technician.
The ceramic heating elements should be periodically inspected particularly for hairline cracks. There is
usually no specific reason for this occurring other than through age due to the expansion & contraction
of the ceramic material. The same applies to the resistance wire within the ceramic case. Although no
warning of failure is visible, if the element fails to heat, then the wire has probably broken inside.
For the reasons stated, the elements, associated cables, connectors, fuses and triac controllers
are specifically excluded from our standard warranty
Replacing a heating element
If the plastic is not being heated evenly and there is an obvious cold spot then follow the below
procedure. This procedure is simplified if the checks ar performed from ‘cold’
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 each zone individually and feel each element
connected to that specific zone. The difference in temperature will quickly become noticeable.
If one or more elements fail to heat then follow below.

19
Service\Repair Formech FM660
Replacing a heating element - continued
Disconnect the electrical mains supply.
Bring the heater completely forward.
Remove the self tapping screws securing the slotted heater cover and place to one side with
the cover. At this stage check that the wiring terminal block connections and the simmerstat
connectors at the front of the heater are fully tightened and that the fault was not merely a loose
connection or a disconnected clip.
Remove the cap from the terminal block associated with the faulty element, loosen the terminal
block screws and remove the element leads and insulation sleeves.
Remove the retaining clip holding the faulty element placing hand underneath heating element
to prevent it from falling. Remove the element.
Push new element into hole and fix spring & clip from top.
Slide on the insulation sleeves, replacing with new if perished or damaged. Ensure that the
connections are fully tightened and correctly wired.
Replace the terminal block cover and check that no cabling is touching any metal parts.
Replace the slotted heater cover and fit the self tapping screws.
Auto-levelling system
This machine is fitted with an automatic sheet levelling system. An optical sensor directs a beam of
infrared light across the machine; a ‘honeycomb’ reflector receives this light and shines it back to the
sensor. If the beam is broken air is pumped onto the base of the machine under the plastic lifting it until
the reflected beam is re-established.
When the plastic is heated it begins to sag and cuts the beam, the compressed air lifts the plastic until it
has cleared the beam. The air is then shut off until the plastic sags again. The intervals between the air
turning on & off may be very short.
The alignment between the optical sensor and the reflector is finely adjusted. It may require re-
adjusting if the machine has been transported or used roughly.
If the heater is left for any time over the forming area (without plastic clamped in) the reflector
may become distorted. The sensor may fail if it is exposed to high temperatures.
The optical sensor is located under the top-frame on the left-hand side. The reflector is opposite.
When the sensor is in the ‘beam received & returned unbroken’ state only the green LED will light.
When the beam is broken the red & green LED’s will light. No other combination will work properly. If
the above LED’s light at the correct time but the Auto-Level does not work properly then either the
beam is shining too low or too high. Alternatively the pneumatic system is failing.

20
Service\Repair Formech FM660
Auto-Levelling system - continued
Adjustment may be carried out by slightly bending the sensor mounting plate or the reflector plate;
certain machines are fitted with an adjustable bracket, which allows for fine trimming of the sensor. The
sensor has two small adjusting screws that alter sensitivity and range. These have been set at the
factory and are unlikely to have moved. Only adjust these if you cannot make the sensor work properly
by any other means.
If no LEDS are visible at any time then the sensor may have lost its power connection or become faulty.
The Auto-Level may be working properly but blows the plastic up higher than the top-frame level. If this
is the case adjust the sensor mounting plate slightly downward.
Test the machine by placing a narrow strip of plastic across the top-frame at right angles to the sensor
approx. midway between sensor and reflector. Clamp the strip in the usual way. Push the plastic down
until the sensor operates.
Vacuum
Warning: never oil any part of the vacuum pump. It is designed to run dry and could be severely
damaged by lubrication.
The vacuum circuit requires very little maintenance. The inlet filter is mounted on the rear external panel
for easy access. Unclip the top cover of the filter box. The paper cartridge filter will prevent small
particles and dust from entering the vacuum pump. This filter should be inspected periodically and
blown out is dirty or replaced if in poor condition. Do not run the machine without this filter.
Worn or damaged seals around the perimeter of the table may cause loss of vacuum. These are
classed as a consumable part and require replacement after some time. To replace seals follow the
procedure on page 21 .
Other causes of vacuum loss are loose or damaged flexible hose from table to metal pipe (at back of
machine) blocked filters or build up of contamination in the vacuum or tank valves. The valves should
be dismantled and cleaned with paraffin or diesel fuel. Be sure to remove all traces of the solvent
used before re-assembling.Lubricants or other liquid may cause irreparable damage to the pump if
introduced into the vacuum circuit.
Vacuum Pump Clinica version (only)
The diaphragm pump fitted will cope with contaminants that dry vane pump cannot and hence the
warnings stated in the standard FM660 user manual relating to dry vane pumps do not apply.
Vacuum filtration - There are two filtration systems fitted to the FM660 Clinica to reduce
contaminated air getting to the diaphragm pump fitted.
Table filter - In the table there is a pit with a filter mounted in the centre. This allows particulate
to fall to the bottom of the pit and not enter the vacuum system. The filter is a fibre cartridge type
designed to reduce plaster particulate and other solid matter entering the vacuum system. The
filter will require cleaning depending upon usage and the amount of wet plaster use during
moulding.
Remove the top cover by rotating anti-clockwise. Wash the filter in clean running water until
clean. Dry and refit. If there is a significant amount of plaster in the pit remove the filter cartridge
holder using the tool provided and clean excessive amounts of plaster from the pit.
Water trap filter- This is mounted on the side or the back of the machine. Drain off excessive
water using the tap on the base. The internal filter may also require cleaning in the same way as
the table filter. Twist the bowl to remove. Ensure the rubber seal is fitted correctly. Apply a small
amount of lubricant to the seal if required to ease fitting and ensure a good vacuum seal.