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.