Shannon HRP/S User manual

User’s Guide
English
Plastic bending machine
HRP/S

User’s Guide
HRP/S
-1-
HS
User’s Guide
Plastic bending
machine
HRP/S
2007 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/S
-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 Upperframe switch 9
4.2 Emergency stop 9
5 Legend 10
5.1 Overview 10
5.2 Switch unit 11
5.3 Air / Timer unit 11
5.4 Timer 11
5.5 Regulating 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 heating elements 14
7.3 Setting temperature 14
7.4 Trouble shooting 14
7.5 Setting cycle time 14
7.6 Foot switch 15
7.7 Setting air pressure 15
8 Adjustment 16
8.1 Safety measures 16
8.2 Lower heating element 16
8.3 Upper heating element and pressure bar 18
8.4Lower filament height 18
8.5 Upper filament height 19
8.6Stop 20

User’s Guide
HRP/S
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HS
Contents
9 Alterations 21
9.1 Safety measures 21
9.2 Lower heating element 21
9.2.1 Removal 21
9.2.2 Installation / replacement 22
9.3 Upper heating element and pressure bar 24
9.3.1 Removal 24
9.3.2 Installation 25
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 Tensioning and changing filament 30
11.1 Safety measures 30
11.2Tensioning 30
11.3Changing 31
12 Fuse 33
12.1Safety measures 33
12.2 Control unit fuse 33
Annexes 34
A Options 34
Accessories 35
Equipment 35
B Service and warranty 37

User’s Guide
HRP/S
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HS
Introduction
Congratulations on purchasing the Shannon HRP/S
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/S. 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/S
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HS
Description of the machine
The Shannon HRP/S 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. Two elements on the bottom and 2 on the top.
The temperature of the heating wires can be adjusted
independently by 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 12 - 15 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 the 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/S
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Technical Data
model
HRP/S
Assembly
control
4
lower heating element
2 (max. 4), fitted with single filament
upper heating element
2 fitted with single filament
pressure bar
2
Electrical
voltage
power
fuse
control unit
220/240 V~
1000 VA
5 AT x2
max. power requirement
4.000 VA
connection
CEE 7/4 16A 2P+A
network connection
CEE 7/4 16A 2P+A
Network ciruitbreaker
Max. 16 A
filament
0-30 V, 0-13 A ~
Pneumatic
air
Unlubricated clean dry air
maximum
6 bar
minimum
5 bar
working pressure
6 bar
coupling
SMC quick action coupling
Mechanical
gradation of stop
0-1000 mm
dimensions 220 machine
dimensions 300 machine
2590x1300x1092 mm (lxwxh)
3390x1300x1092 mm (lxwxh)
weight 220 machine
weight 300 machine
500 Kg
650 Kg.
life of filament
approx. 600 hours
Functional
bending width
2.200 mm or 3.000 mm.
mutually extendible
25 - 1000 mm
sheet thickness
1 - 12 mm
setting range timer
0-300 sec
temperature range filament
20-550 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
1,5, 3, 5, 6mm 1 x set
spare fuse
6.3x32 5 AT 4 x
spare filament
1.6 4 x
2

User’s Guide
HRP/S
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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 15 mm
thick.
3

User’s Guide
HRP/S
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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/S
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Safety devices
The machine is equipped with the following safety devices:
4.1 UPPERFRAME-SWITCH
When the upperframe-switch is touched the machine opens.
This avoids limbs becoming trapped. The timer (D, page 11) is
returned to zero.
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. By using the emergency
stops the top frame lifts up.
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.
Turning and pulling it out until a click is heard resets the
emergency stop button.
4

User’s Guide
HRP/S
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Legend
5.1 OVERVIEW
5
Front
Rear
Top frame
Upper heating element
Pressure bar
Upperframe switch
Stop
Gradation
Emergency stop button
Foot switch
Control unit
Air / timer unit and footswitch connection
Bearing block
Lower heating element
Working surface
Air connection
Power supply cable
connection

User’s Guide
HRP/S
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HS
Legend 5
5.2 SWITCH UNIT
This contains the main switch of the machine.
5.3 AIR / TIMER UNIT
The air / timer unit is the combined unit for operation of the top
frame, monitoring of the upperframeswitch and setting the
cycle time (F). When the footswitch (connection A) is operated,
the machine closes. The counter begins to run when the
machine is fully closed. At the end of the pre-set time, the top
frame opens. The counter is then returned to 0.
A Connection foot switch
B On/off switch
C Emergency button
DTimer unit
5.4 TIMER UNIT
There are 3 numbers on the display. From E to G the
numbers mean:
E. The time that the machine will buzz
F. The time that the machine is closed. The
time will start when the machine is
entirely closed
G. The time till the machine opens again
Button
Function
Esc
cancel
+
increase value
-
decrease value
OK
confirm
►
move right
▼
move down
▲
move up
◄
move left
F
E
G
C
B
A
D

User’s Guide
HRP/S
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HS
Legend 5
5.5 CONTROL UNITS
The control unit contains an electronic controller that can be
used to set the temperature of the filament
H. On/off switch
I. Temperature adjustment
J. Connection to filaments
K. Connection to 220 V AC
L. Fuse

User’s Guide
HRP/S
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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. 6 bar).
3. Using a quick-action coupling connect the rear of the
machine to your compressed air system or compressor.
4. Slowly open the reducing valve (turn to the right) and set
the air pressure in the system at 6 bar.
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
Insert the plugs of the foot switch into the connection (A,
page 11)(numbered 1& 2)
6

User’s Guide
HRP/S
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Operation
7.1 PREPARATION
1. Check that the air pressure is connected.
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 off all regulating units.
7.2 SWITCHING ON HEATING ELEMENTS
Each heating element can be switched on and controlled
individually.
1. Switch on control unit with switch H. (see 5.5, page 12)
7.3 SETTING TEMPERATURE
The temperature of the filament can be set using the
temperature control.
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

User’s Guide
HRP/S
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HS
Operation 7
7.4 TROUBLE SHOOTING
7.5 SETTING CYCLE TIME
The time during which the machine is closed to heat the plastic
sheet on two sides can be set on the timer unit.
At first use of the machine, set E = 5 and F = 20 (See 5.3)
1. Switch between values with the ▼/▲buttons.
2. Increase or decrease the value with the +/-
buttons.
3. Cancel the value with the “ESC” button.
4. Confirm the value with the “OK” button.
7.6 OPERATE FOOT SWITCH
The top frame is served by pressure on the pedal of the foot
switch.
7.7 SETTING AIR PRESSURE
The pressure for the system is adjusted by the factory on the
right value (6 bar).
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

User’s Guide
HRP/S
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HS
Adjustment
8.1 SAFETY MEASURES
Always take the following safety measures before adjusting the
heating elements:
1. Ensure that the upper heating elements and pressure bars
is firmly attached.
2. Switch off the heating elements one at a time
(Switch H).
3. Clear the working surface.
4. 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/S
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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/S
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HS
Adjustment 8
8.3 UPPER HEATING ELEMENT AND
PRESSURE BAR
1. Disengage the air connection (page 13)
The top frame will then slowly lower while air escapes.
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

User’s Guide
HRP/S
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HS
Adjustment 8
8.5 UPPER FILAMENT HEIGHT
Make sure that the lower and upper heating elements and the
pressure bars are in the correct position.
1. Set the timer (F, page 12) to 990 sec.
With this time setting the machine will remain closed for
long enough to adjust the filament height.
2. Place a test piece of the plastic to be processed on the
working surface.
3. Lower the top frame by pressing the footswitch.
5. Adjust the height of the filament using the adjusting nuts
on the upper heating elements.
You can set the filament to a minimum of 6 mm above the
plastic.
Adjust the height so that the element is clear of the plastic.
6. Open the top frame with the emergency button (C, page
11) and reset the button.
7. Reset the timer (F, page 11).
8. Start the machine again as in Section 7.
Adjusting nuts
5