Shannon AFF/D 135 User manual

User’s Guide
English
Plastic bending machine
AFF/D 135

AFF/D 135
12-2-2015
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Matt Asselman
1USER’S GUIDE
Plastic bending machine
AFF/D 135
2013 SHANNON BV. All rights reserved.
No part of this User's Guide may be photocopied, altered or
translated without prior written consent.
Information contained in this User's Guide is subject to change
without notice

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2TECHNICAL DATA
type
AFF/D 135
Assembly
Control unit
Max.
2
Upper heating element
Max
2
Pressure bars
2
Electrical
Control unit
Voltage
220 –240 V AC
Power
520VA
Fuse
2,5 AT x2
Timer unit
Voltage
220 –240 V AC
Power
5VA
Fuse
2,5 AT x2
connection
CEE 7/4 16A 2P+A
Network connection
CEE 7/4 16A 2P+A
Network circuit breaker
Max. 16 A
Pneumatic
Air
Unlubricated clean dry air
Maximum
6 bar
Minimum
5 bar
Operating pressure
6 bar
Coupling
Quick action coupling
Mechanical
Gradation of stop
0-500 mm
dimensions
[LxWxH]
850 x 1510 x 380 mm
weight
200 Kg
Functional
Bending width
1350 mm
Sheet thickness
0,2 - 1 mm
Temperature element
Max
220 ◦C
Ambient
Temperature
18-30 C
Humidity of the air
50-80 % (no condensed)
Miscellaneous
set of socket screws keys
1 set [1½, 3, 5 mm]
Spare fuse
4 x [6.3x32 2,5 AT]

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3CONTENTS
2 Technical data 2
3 Contents 3
4 Introduction 4
5 Description of the machine 5
6 Safety instructions 6
7 Safety precautions 8
8 Legend 9
8.1 Summary 9
8.2 Air/Timer Unit 10
8.3 Timer Unit 10
8.4 Control Unit 11
9 Installation 12
9.1 Assembly 12
9.2 Connecting air/timer unit 12
9.3 Connecting foot switch 12
9.4 Connecting compressed air 12
9.5 Connecting power 12
10 Operation 13
10.1 Preperation 13
10.2 Switching on heating element 13
10.3 Setting temperature 13
10.4 Setting cycle time 13
10.5 Foot switch 14
10.6 Setting air pressure 14
11 Adjustment 15
11.1 Safety precautions 15
11.2Pressure bar 15
11.3Upper element height 15
11.4 Stop 16
11.5Angular stop 16
12 Maintenance 17
12.1Safety precautions 17
12.2 Lubrication points 17
12.3 Profiles 17
12.4 Water seperator 17
13 Fuses 18
Annexes 19
A Options 19
Accessories 19
B Equipment 20
Service and warranty 21

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4INTRODUCTION
Congratulations on purchasing Shannon’s plastic bending machine AFF/D 135. Read this guide
completely before installing and using the machine.
We want to keep in contact and to know how you find the AFF/D 135. We are always willing to
advise on the use of the machine and its accessories.
SHANNON BV
Turfschipper 11-13
2292 JC Wateringen
P.O. box 84
2290 AB WATERINGEN
the Netherlands (EC)
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Website: www.shannon.nl

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5DESCRIPTION OF THE MACHINE
The Shannon AFF/D bending machine is a semi-automatic machine for the production of large series of
items with one or two bends for the plastic sheet processing industry.
The machine has two heating elements. The temperature of which can be adjusted by electronic controls.
The heating elements which are mounted in the pneumatically operated top frame are adjustable in height
in respect of the working surface.
One of the heating elements can be moved in the top frame to create a certain distance between the 2
bends.
The workpiece can be heated from one side by contact, reducing the production cycle time and making it
possible to bend sheet up to 1 mm thick.
The top frame is switched on independently of the control unit and is controlled by an adjustable timer.
The working surface is made of scratch-resistant solid core material to support the plastic sheet.
When heated, thermoplastics become so flexible that they can be shaped. When a plastic sheet is heated to its
softening point in a narrow zone, if can be bent to any angle desired.
The bending radius is determined by the width of the heated zone. The zone is determined by the thickness of
the material and the type of heating element.
Every plastic has its specific softening point. By coordinating the temperature, heated zone and the heating
time all kinds of thermoplastic can be processed.

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6SAFETY INSTRUCTIONS
To ensure safety when using the machine you should read this
User's Guide carefully and follow the safety instructions closely
Attention!
The machine contains a section where there is a risk of trapping.
Attention!
The machine contains parts, which are hot. Touching them will
cause burns.
Allow hot parts to cool sufficiently (at least 10 minutes) before
touching them.
Never touch the heating elements when the machine is in
operation.
Always wear close-fitting clothing.
Be particularly careful of sleeves and always tie back long hair.
Never leave objects on the working surface.
The machine may only be used for heating narrow zones in flat
plastic sheet.
Any other use could lead to very hazardous situations or cause
damage to the machine!
The plastic sheets that have to be bent may never be thicker than
1 mm.
Before commissioning and servicing always check the connection
cable and plug for defects.
When servicing switch off the machine and remove the plug from
the socket.

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Before use always check that all the pressure bars and heating
elements in the top frame are firmly attached.
Never operate the machine if anyone is standing close behind or
beside it.
Never introduce objects or material into the machine from the
rear.
Never leave the machine unattended without switching it off.

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7SAFETY PRECAUTIONS
EMERGENCY STOP
There is an emergency stop button (C) at the front of the air/timer unit, which can be reached by
the operator from the normal working position.
Pressing the emergency stop button switches off the timer and the top frame lifts up. The button
remains pushed in.
Resetting of the emergency button comes to pass by turning the button to the right.
The machine is ready to use again.
ONLY USE THE EMERGENCY STOP BUTTON WHEN:
oRisk of trapped limbs.
oDefects in the timer, so the machine fails to open after the pre-set time.
oAn outbreak of fire or situations involving a risk of fire.
oAny situation that might present a risk to people or animals.
oAny other situation, that might present a risk or cause, damage to the machine and/or
objects.

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8LEGENDA
SUMMARY
The legenda of the entire machine.
Topframe
Heating element
Control unit
Pressure bar
Stop
Gradation
Working surface
Timer unit
Flip
Vacum

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AIR/TIMER UNIT
The air/timer unit is a combined unit for the control of the
topframe and to set the cycle time.
The machine closes, when the foot switch is used. The
timer will start when the machine is proper closed. The
machine opens again when the time reached its value. The
plastic sheet is then held into place by a vacum system,
and the flip is turned to bend the plastic sheet
automatically. The angle in which the sheet it bent can be
set manually (See 13.5). While the sheet is bent, cool air is
blown onto the crease to cool the sheet. The timer will
then reset back to zero
A. Connection foot switch
B. On/off switch
C. Emergency button
D. Timer unit
TIMER UNIT
Button
Function
Esc
cancel
+
increase value
-
decrease value
OK
confirm
►
move right
▼
move down
▲
move up
◄
move left
There are three numbers on the screen. From E
to G the number means the following; (see 10.4)
E. The time that the machine is closed. The time will start when the machine is entirely closed.
F. The time that the flip is in the turned position, and the sheet is being cooled.
G. The number of times the cycle has been repeated.
D
C
A
B
E
G
F

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CONTROL UNIT
The control unit contains an electronic controller that can be used to set the temperature of the
element (see 10.3).
H. On/off switch.
I. Temperature adjustment.
L. Fuses.
H
I
L
Front

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9INSTALLATION
ASSEMBLY
1. Remove packaging and blocking of top frame.
2. Place the machine on a level floor with sufficient space around and above the machine.
3. Ensure there is adequate ventilation and lighting at the workplace.
4. Avoid draughts, in order to prevent uneven heating.
CONNECTING AIR/TIMER UNIT
1. A black tube that is coming out of the machine has three air tubes. Connect the tubes to the
corresponding number of the air/timer unit (at the backside).
2. The black tube contains a gray wire which splits into a blue and brown 1, with an iron mantle.
Connect the mantles with the red plugs which come out of the air/timer unit (at the backside).
3. On the left side (Below the working surface) you’ll find 4 air tubes. Connect these air tubes to
the corresponding numbers of the air/timer unit (at the left side)
CONNECTING FOOT SWITCH
Connect the plug of the foot switch on the corresponding socket (a) at the front side of the
timer unit. See 8.2
CONNECTING COMPRESSED AIR
1. Check that the heating elements and pressure bars in the top frame are firmly attached.
2. Using a quick-action coupling connect the left of the machine to your compressed air system or
compressor.
CONNECTING POWER
1. Check that all switches of the control units are in the 0-position.
2. Put the plug into the socket.

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10 OPERATION
PREPARATION
1. Check that the air pressure is connected.
2. Clear the working surface.
3. Check that the heating element is connected to the control unit.
4. Check that all the upper heating element and pressure bars are firmly attached to the top
frame.
5. Make sure to tape off the vacuum cups that will not be used, using the masking tape provided
with the machine. This ensures the material stays sucked to the working surface.
SWICHTING ON HEATING ELEMENT
1. Switch on control unit with switch(H) (see 8.4).
SETTING TEMPERATURE
The temperature of the element can be set using the
temperature control.
1. Press button A to enter the temperature setting
2. To increase the temperature, push button B
3. To decrease the temperature, push button C
4. Press button A to exit the temperature setting, or
wait 30 seconds.
5. Check if the heating element warms up (do not touch
the element, due to risk of burning yourself)
SETTING CYCLE TIME
The time during which the machine is closed to heat the plastic sheet can be set on the timer
unit. At first use of the machine, set E = 3 and F = 5 (see 10.3)
1. Switch between values withe the ▼/▲buttons.
2. Increase of decrease the value with the +/- buttons
3. Cancel the value with the “ESC” button
4. Confirm the value with the “OK” button
FOOT SWITCH
The top frame is served by pressure on the pedal of the foot switch.
SETTING AIR PRESSURE
The pressure for the system is adjusted by the factory on the right value (6 bar).
C
B
A

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11 ADJUSTMENT
SAFETY PRECAUTIONS
Always take the following safety precautions before adjusting the clamp bars:
1. Ensure that the upper heating elements and pressure bars are firmly attached.
2. Switch off the heating elements (switch H).
3. Clear the working surface.
4. Allow the heating elements to cool for at least 10 minutes.
PRESSURE BAR
1. Disconnect the air connection.
2. The top frame will then slowly lower while air escapes.
3. Loosen the socket head screws on the support bar clamps of the pressure bar or secondary
heating element one turn. The primary heating element (which is marked red on the socket
head screw) should remain in its current position.
4. Hold the pressure bar at the sides, left and right, and slide it into the desired position. Move
the support bar parallel to the front of the top frame.
5. Tighten the support bar clamps again.
6. Switch on the machine again as in Section 12.
The upper heating elements and pressure bars may fall out of the top frame if they are loose
or not properly attached.’
UPPER ELEMENT HEIGHT
1. Switch off the heating elements (Switch H).
2. Allow the heating elements to cool for at least 10 minutes.
3. Set the timer (E) to at least 60.0 sec. (see 10.4). With this time
setting the machine will remain closed for long enough to adjust
the element height.
4. Place a test piece of the plastic to be processed on the working
surface.
5. Lower the top frame (foot switch).
6. Adjust the height of the element using the adjusting nuts on the upper heating elements.
7. Adjust the height so that the element only just touches the plastic (the element must touch the
plastic, but not push it down).
8. Open the top frame by pressing the emergency stop (C), or by letting the timer run out.

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9. Reset the emergency stop if necessary.
10. Adjust the timer (D) again.
11. Start the machine again as in section 10.
LOWER VACUM & FLIP SYSTEM
1. Switch off the heating elements (Switch H).
2. Remove the strips of solid core material next to the vacuum & flip
system to be adjusted by loosening the two socket head screws
(use socket screw key no. 5).
3. Loosen the socket head screws in the bottom of the small block
on both sides of the flip system. You can now slide the system to a
different location.
4. Loosen the socket head screws in the vacuum system. You can
now slide the system to a different location.
STOP
1. Loosen the nuts on the parallel stop one half turn.
2. Slide the stop into the desired position.
3. Hold the guide parallel to the front of the machine.
This stops the clamping blocks from binding.
4. Tighten the nuts.
Always ensure that the stop is placed in such a way that heating elements or pressure bars
cannot hit the stop as they are lowered.

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ANGULAR STOP
1. Loosen the nut on the protractor.
2. Slide the nut into the desired position.
3. Tighten the nut.
4. Run the machine with a piece of test plastic, to check if the set angle is accurate enough.
If you do not wish to use the secondary bend, simple close the faucets on the left side of the
machine. The red faucet is for the vacuum (turning this 1 off is not mandatory to cancel the 2nd
bend), the blue faucet is the flip-over system.
This cuts off the air supply to the secondary bend, and only the primary will be in use. Don’t
forget to turn off the heating element of the secondary bend as well!

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12 MAINTENANCE
This machine needs little maintenance. Remove loose dirt once in a while.
SAFETY PRECAUTIONS
1. Switch of the regulating unit (Switch H).
2. Clear the working surface.
3. Disengage the air connection.
4. Remove the plug from the socket.
LUBRICATION POINTS
The following points should be lubricated with a drop of oil or grease once a year:
1. Bearing cilinder: underside.
2. The lubrication point can be accessed from the rear of the machine.
3. Bearing cilinder: upperside.
4. The lubrication point can be reached by removing the solid core strips on the middle of the
machine.
PROFILES
The heating element works more effectively when it is clean. Remove dirt and deposits from the
heating elements regularly. Blow away loose dirt and brush them clean.
WATER SEPARATOR
Check if there is water in the water separator and remove it if necessary. The water separator is
situated on the backside of the air/timer unit. If there is water in the glass holder, it should be
drained off.
1. Disengage the air connection.
2. The top frame will lower slowly.
3. Hold a container under the nipple and slowly open the nipple. All the water will then run out of
the glass holder.
4. Close the drain nipple by hand.
5. Switch the machine on again as described in Section 10.

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13 FUSES
A maintenance engineer should always be alerted when a fuse blows. Do not replace the fuse
until the short circuit has been corrected.
SAFETY PRECAUTIONS
Before replacing a fuse always take the following safety precautions:
1. Switch the control unit off (Switch H).
2. Remove plug from socket.
FUSES CONTROL UNIT
1. Open the fuse holder (L) by pushing it in and turn to the left. The fuse will come out.
2. Verify and replace the fuse (if necessary) in the reversed order.
N.B. Fuse 6,3x32mm; 2,5 AT.
FUSES TIMER UNIT
The fuses of the Timer unit are located at the backside.
1. Open the fuse holder by pushing it in and turn to the left. The fuse will come out.
2. Verify and replace the fuse (if necessary) in the reversed order.
N.B. Fuse 5x20mm; 2,5 AT.
L
I
H

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OPTIONS
Service contract
Shannon BV offers you the possibility to close a service-contract.
Accessories
Shannon BV can supply various accessories and production equipment for the processing of plastic sheet.
AFF Heating element
Easily replaceable heating element for the AFF machines.
Different contact-back sizes are available.
Working width of reducing set
Working width of reducing set for heating one or more zones per bending line.
Foilbending profile
A contact profile with anti-stick coating suitable for bending thin sheets from 0.3 - 2 mm.
Profile lengths: 500, 650, 1.000 en 1.250 mm
Ridge widths: 1 to 10mm
Number of ridge widths: single and double
Special versions : on request