Shannon HRP 220 User manual

User’s Guide
English
Plastic bending machine
HRP 220

User’s Guide
HRP 220
-1-
HS
User’s Guide
Plastic bending
machine
HRP 220
1995 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.

User’s Guide
HRP 220
-2-
HS
Contents
Contents 2
Introduction 4
1 Description of the machine 5
2 Technical data 6
3 Safety instructions 7
4 Safety devices 9
4.1 Ribbon switch 9
4.2 Emergency stop 9
4.3Air pressure monitoring 9
5 Legend 10
5.1 Overview 10
5.2 Switch unit 11
5.3 Timer unit 11
5.4 Control unit 12
6 Installation 13
6.1 Assembly 13
6.2 Connecting compressed air 13
6.3 Connecting power cable 13
6.4Connecting foot switch 13
7 Operation 14
7.1 Preparation 14
7.2 Switching on control units 14
7.3 Switching on top frame 14
7.4 Switching on heating elements 15
7.5 Setting temperature 15
7.6 Trouble shooting 16
7.7 Setting cycle time 15
7.8 Hand or foot operation 16
7.9 Setting air pressure 16
7.10Resetting ribbon switch 16
8 Adjustment 17
8.1 Safety measures 17
8.2 Lower heating element 17
8.3 Upper heating element and pressure bar 19
8.4Lower filament height 19
8.5 Upper filament height 20
8.6Stop 21

User’s Guide
HRP 220
-3-
HS
Contents
9 Alterations 22
9.1 Safety measures 22
9.2 Lower heating element 22
9.2.1 Removal 22
9.2.2 Installation/replacement 23
9.3 Upper heating element and pressure bar 25
9.3.1 Removal 25
9.3.2 Installation 26
10 Maintenance 27
10.1 Safety measures 27
10.2 Lubrication points 27
10.2.1 Cylinder bearing: bottom 27
10.2.2 Cylinder bearing: top 27
10.2.3 Bearing blocks 28
10.3 Profiles 28
10.4 Water separator 28
10.4.1 Checking 28
10.4.2 Emptying 29
11 Trouble shooting 30
12 Installation and removal of units 31
12.1Safety measures 31
12.2 Control unit 31
12.2.1 Removal 31
12.2.2 Installation 32
12.3 Timer/switch unit 33
12.4 Main switch box 33
12.4.1 Removal 33
12.4.2 Installation 34
13 Tensioning and changing filament 35
13.1Safety measures 35
13.2 Tensioning 35
13.3 Changing 36
14 Fuse 38
14.1 Safety measures 38
14.2 Control unit fuse 38
14.3 Restoring circuit breaker 39
14.4 Main switch box fuse 39
Annexes 40
A Machine summary 40
B Diagram control unit 41
C Diagram timer unit 42
D Diagram switch unit 43
E Diagram pneumatic system 44
F Dimensions 45
G Options 46
Accessories 47
Equipment 47
H Service and warranty 49

User’s Guide
HRP 220
-4-
HS
Introduction
Congratulations on purchasing the Shannon HRP 220 plastic
bending-machine.
Read this Guide completely before installing and using the
machine.
We want to keep in contact and to know how you find the HRP
220. 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

User’s Guide
HRP 220
-5-
HS
Description of the machine
The Shannon HRP plastic bending-machine is a rapidly
convertible semi-automatic machine for the production of large
series of items with multiple bends for the plastic sheet
processing industry.
The machine has four adjustable heating elements as
standard, the temperature of which can be adjusted by
electronic controls.
The filaments of the heating elements on the working
surface are adjustable in height. The other elements, which
are mounted in the pneumatically operated top frame which
clamps the workpiece in place, are adjustable in height as a
single unit in respect of the working surface.
The workpiece can be heated from two sides, considerably
reducing the production cycle time and making it possible to
bend sheet up to 20 mm thickness.
The top frame is switched on independently of the control
units and is controlled by an adjustable timer.
The working surface is made of scratch-resistant solid core
material with which the space between the zones to be
heated can be filled to support the plastic sheet.
The machine has facilities for the mounting of additional
heating elements at both top and bottom. The elements can
be mounted by the user.
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,
the type of heating element and the distance between the
plastic and the filament.
Every plastic has its specific softening point. By co-ordinating
the temperature, heated zone and heating time all kinds of
thermoplastic can be processed.
1

User’s Guide
HRP 220
-6-
HS
Technical Data
model
HRP 220 Standard
Assembly
control
4 (max. 8)
lower heating element
2 (max. 4), fitted with single filament
upper heating element
2 (max. 4), fitted with single filament
pressure bar
2 (max. 4)
options
see Annex G
Electrical
voltage
power
fuse
timer unit
24 V=
15 VA
100mAT
switch unit
380/220 V~
20 VA
250 mAT
control unit
220/240 V~
1000 VA
5 AT
max. power requirement
8.000 VA
circuit breaker
3x16 A
connection
CEE 4 32A 3P+0+A
network connection
CEE 4 32A 3P+0+A
Network ciruitbreaker
Min 3x16 A
filament
0-30 V, 0-19 A ~
diagram
see Annex B, C and D
Pneumatic
air
Unlubricated clean dry air
maximum
8 bar
minimum
3.5 bar
working pressure
6 bar
coupling
Festo quick action coupling
air consumption
21.6 Nl per cycle at 6 Bar
diagram
see Annex E
Mechanical
speed of top frame
 rad/s (20cm/s at front)
response time ribbon switch
100 ms
force on plastic
approx. 3.5 kg/cm²
gradation of stop
0-1000 mm
dimensions
2590x1300x1092 mm (lxwxh) see Annex F
weight
650 Kg
life of filament
approx. 600 hours
Functional
bending width
2200 mm
mutually extendible
1000 mm (max.)
sheet thickness
1 - 20 mm (depending on heating element)
setting range timer
0-9999 sec
temperature range filament
20-600 C
filament height adjustment
bottom
1 - 17.5 mm
top
7 - 26 mm
Ambient
temperature
18-30 C
humidity of the air
50-80 % (no condensed)
Miscellaneous
set of socket screw keys
2, 3, 5, 6mm 1 x
spare fuse
5x20mm 250 mAT 1 x
spare fuse
6.3x32 5 AT 4 x
spare filament
1.6 x 2350 mm 4 x
2

User’s Guide
HRP 220
-7-
HS
Safety instructions
SAFETY 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 filaments or the reflectors 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 sheet to be bent should never be more than 20 mm
thick.
3

User’s Guide
HRP 220
-8-
HS
Safety instructions 3
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.
When the machine is temporarily out of use always remove
the foot switch and keep it in a safe place.
Before use always check that all the pressure bars and heating
elements in the top frame are firmly attached.
Only switch on those heating elements which are needed.
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.

User’s Guide
HRP 220
-9-
HS
Safety devices
The machine is equipped with the following safety devices:
4.1 RIBBON SWITCH
When the ribbon switch is touched the power on the top frame
is interrupted and the machine opens. This avoids limbs
becoming trapped. The red lamp (J) on the timer unit lights and
the timer (K) is returned to zero (see also § 5.3.) The timer unit
must be reset after a stop.
4.2 EMERGENCY STOP
There is an emergency stop button at the front of the machine
on the left and right, which can be reached by the operator
from the normal working position. The pedal switch has also an
emergency stop function, when it is pushed in completely. By
using the emergency steps the electrical power of the
regulating units, will be disconnected and the top frame lifts up.
(see also § 5.2)
Only use the emergency stop buttons in the following
situations:
Risk of trapped limbs.
Defects in the timer, so the machine fails to open after the
pre-set time.
An outbreak of fire or situations involving a risk of fire.
Any situation which might present a risk to people or
animals.
Any other situation, which might present a risk or cause,
damage to the machine and/or objects.
When the emergency situation has been remedied, the
emergency stop button must be reset and the various functions
switched on again individually.
Pulling it out until a click is heard resets the emergency stop
button. Pushing the blue button, which is mounted, on the
pedal switch will reset the food pedal.
4.3 AIR PRESSURE MONITORING
The machine switches off if the air pressure fails.
The lamp in the main switch Aremains alight.
When the pressure is restored the top frame lifts up again. The
machine must then be started up again.
4
Reset

User’s Guide
HRP 220
-10-
HS
Legend
5.1 OVERVIEW
5
Front
Rear
Top frame
Upper heating element
Pressure bar
Ribbon switch
Stop
Gradation
Emergency stop button
Foot switch
Switch unit
Timer unit
Control unit
Pressure regulator
Bearing block
Lower heating element
Working surface
Foot switch connection
Air connection
Power supply cable
connection

User’s Guide
HRP 220
-11-
HS
Legend 5
5.2 SWITCH UNIT
This contains the main switch (A) of the machine and the push
button switches to start the heating and the top frame.
AMain switch.
heating
BSwitch on control units (also reset button for emergency stop).
CSwitch off control units.
top frame
DSwitch on top frame.
ESwitch off top frame.
5.3 AIR/TIMER UNIT
The timer unit is the combined unit for operation of the top
frame (Gand H), Operating the buzzer (Iand J) and setting the
cycle time (K). When the foot or push-button (H) switch is
operated, the machine closes. The counter begins to run when
the machine is fully closed, afterwards the switch can be
released. At the end of the pre-set time, the top frame opens
and the buzzer (J) makes a whistling sound for a few seconds.
This sound can be turned off by switch (I). The counter is then
returned to 0.
FSelector switch foot/hand operation.
GTop frame up.
HTop frame down.
IBuzzer on/off.
JBuzzer.
K Electronic timer.
B
C
A
D
E



User’s Guide
HRP 220
-12-
HS
Legend 5
5.4 CONTROL UNITS
The control unit contains an electronic control with which the
temperature of a filament is set.
L Switch on/off (green lamp).
M Temperature adjustment
NConnection to filaments
OConnection to 220V ACL
PFuse
N
O
P
L
M

User’s Guide
HRP 220
-13-
HS
Installation
6.1 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. Level the working surface of the machine, using shims
under the feet if necessary.
4. Ensure there is adequate ventilation and lighting at the
workplace.
5. Avoid draughts, in order to prevent uneven heating.
When moving the machine with a forklift truck ensure that the
machine is supported right in the centre.
Also use sufficiently long prongs on the forklift truck.
6.2 CONNECTING COMPRESSED AIR
1. Check that all heating elements and pressure bars in the
top frame are firmly attached.
2. Check the air pressure in your system (max. 8 bar).
3. Close the reducing valve on the air unit (turn to the left).
Unlock if necessary (pull out).
4. Using a quick-action coupling connect the rear of the
machine to your compressed air system or compressor.
5. Slowly open the reducing valve (turn to the right) and set
the air pressure in the system at 6 bar (see 7.8, page 16).
6.3 CONNECTING POWER CABLE
1. Check that the rating of the electrical system is adequate
(see technical data).
2. Check that the main switch Ais in the -position.
3. Plug in the machine.
6.4 CONNECTING FOOT SWITCH
1. Insert the plug of the foot switch into the connection on
the side of the machine. The plug will click into place.
N.B. To remove the foot switch the small stop above the
plug must be pressed.
6
25cm

User’s Guide
HRP 220
-14-
HS
Operation
7.1 PREPARATION
1. Check that the air pressure is set at 6 Bar (see 7.8, page
16).
2. Clear the working surface.
3. Check that all the heating elements are connected to the
control units.
4. Check that no scraps of material remain in the reflectors.
5. Check that all the upper heating elements and pressure
bars are firmly attached to the top frame.
6. Turn the potentiometers in the control units to "0".
7. Switch off all the control units (position "").
8. Turn on the main switch A(position I).
The red lamp in switch Cwill light.
The yellow lamp in switch Ewill light.
If switch F is set to Hand Operation, the yellow lamp in
switch Hwill light.
7.2 SWITCHING ON CONTROL UNITS
The power supply to the control units must be switched on
separately.
1. Press switch B.
The red lamp in switch Cwill go out..
The green lamp in switch Bwill light.
The control units are now ready for use!
7.3 SWITCHING ON TOP FRAME
The top frame is switched on separately. The safety system
with the ribbon switch must then be released.
1. Press switch D.
The yellow lamp in switch Ewill go out.
The green lamp in switch Dwill light.
7

User’s Guide
HRP 220
-15-
HS
Operation 7
7.4 SWITCHING ON HEATING ELEMENTS
Each heating element can be switched on and controlled
individually.
Switch on the desired control unit with switch (L). See 5.4.
7.5 SETTING THE TEMPERATURE
The temperature of the filament can be set using the
temperature regulator.
1. When turning on the on/off switch, the display will show the
value that was last saved (keeping the machine on a certain
value for >20 seconds will make it remember this value).
2. Press the right button (arrow up) to increase the value, up to
99 (keeping this pressed in will make the value cycle much
faster)
3. Press the left button (arrow down) to decrease the value,
down to 00 (keeping this pressed in will make the value cycle
much faster)
4. Press both buttons at the same time to go directly to 00.
Doing this also resets the machine.
7.6 TROUBLE SHOOTING
Error message
Meaning
Solution
E1
The wire is loose (not connected)
Turn off the machine, check the filament, and reset the
machine
(see §9.1 for changing filament)
Note: Between the values 00 and 04, this fault cannot be
detected
E2
The wire is loose (spark detection)
Check the connection of the filament
Check the filament, and reset the machine
This fault can also be reset by the arrow down button
(see §9.1 for changing filament)
E9
Broken circuit board
Contact the supplier for a new circuit board
Empty display
No power
Alert a maintenance engineer
Check the fuse (see §10.1)
Check the power supply cable
Contact the supplier if necessary
80

User’s Guide
HRP 220
-16-
HS
Operation 7
7.7 SETTING CYCLE TIME
The time during which the machine is closed to heat
the plastic sheet on two sides is set using the
electronical timer K.
7.8 HAND OR FOOT OPERATION
Select hand or foot operation using switch F.
Position 1: Hand operation.
The frame closes when switch His
pressed.
Position 2: Foot operation.
The frame closes when the foot pedal is pressed.
Press switch G(arrow up) to open the machine before the end
of the set time. The timer (K) is returned to 0.
7.9 SET AIR PRESSURE
Control the pressure in the system with reducing valve
M, which can be found on the water separator (see
10.4, page 28). The air pressure is set by the factory at 6
bar.
N.B. To right: valve open
To left: valve closed
press knob in: lock
pull knob out: unlock
Always lock the reducing valve when the air is being
disconnected from the machine.
7.10 RESET RIBBON SWITCH
When the ribbon switch is touched the machine opens
immediately. It is then impossible to close the machine with the
foot switch or pressure switch H. The red lamp Ewill light. Press
switch Dto start the machine again. The green lamp in switch D
will light.
M

User’s Guide
HRP 220
-17-
HS
Adjustment
8.1 SAFETY MEASURES
Always take the following safety measures before adjusting the
heating elements:
1. Switch off the foot switch by setting switch Fto hand
operation (page 11).
2. Ensure that the upper heating elements and pressure bars
is firmly attached.
3. Switch off the heating elements one at a time (Switch L).
4. Switch off the control units and top frame (Switches Cand
E, page 11).
5. Clear the working surface.
6. Allow the heating elements to cool for at least 10 minutes.
8.2 LOWER HEATING ELEMENT
1. Remove the strips of solid core material next to the
heating element to be adjusted by loosening the two
socket head screws. (Use socket screw key no. 5).
2. Loosen the socket head screws in the supporting prongs
on the left and right of the heating element one half turn.
8
10 minutes
2
Supporting prong
1

User’s Guide
HRP 220
-18-
HS
Adjustment 8
3. Loosen the socket head screw in the centre of the heating
element one half turn.
(Use socket screw key no. 3)
4. Take the heating element with both hands close to the
supporting prongs on the left and right and slide it into the
desired position.
Hold the heating element parallel to the front of the
machine and the supporting prongs. This prevents the
notched nuts in the aluminium X-profiles from binding.
5. Hand tighten the socket head screws, starting in the
supporting prongs and then in the centre.
6. Position the other profiles in the same way if necessary.
7. Fill up the space between the heating elements as far as
possible with solid core strips and hand tighten them. First
slide the notched nuts into the aluminium X-profile
roughly level with the holes and then lay the solid core
strip on top.
8. Switch on the machine again as in Section 7.
3
4

User’s Guide
HRP 220
-19-
HS
Adjustment 8
8.3 UPPER HEATING ELEMENT AND
PRESSURE BAR
1. Disconnect the compressed air.
The top frame will then slowly lower while air escapes.
The power is automatically switched off.
2. Loosen the socket head screws on the support bar clamps
one turn. (Use socket screw no. 6).
3. Take hold of the heating element 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, so that
you position the top filament above the bottom one.
4. Tighten the support bar clamps again.
5. Switch on the machine again as in Section 7.
The upper heating elements and pressure bars may fall out of
the top frame if they are loose or not properly attached.
8.4 LOWER FILAMENT HEIGHT
1. Adjust the height of the filament using the knurled nut.
These can be reached from the sides. Make sure that the
filament height is the same on both sides.
2. Start up the machine again as in Section 7.
Knurled nut
1
2
3
Support bar clamp