FORMTECH 300XQ Manuale di servizio

-

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Formech

forming

to

perfection

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.

Installation,

Operating

and

Service

Manual

User Manual

Contents

Safety ................

..

.

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.

...

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3

Introduction and initial assembly ........................................................................

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.6

Optional extras........

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........................................................7

General Arrangement .......................

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.8

Operating procedures ..................................

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.......................... 10

BASIC

OPERATION

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F.A.Q.

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Warranty..........................................

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14

Service I Repair .......................

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........................................... 15

A.

REPLACING

SEALS

..........

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....................15

B.

REPLACING

A

HEATING

ELEMENT

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16

C.

ELECTRICAL

TROUBLESHOOTING

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17

D.

VACUUM/PRESSURE

TROUBLESHOOTING

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19

Schematics

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......................................................20

Page

2

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L

r

L

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Safety

Thank you

for

choosing Formech.

Please

read and follow the below safety instructions before attempting

to

install

or

operate your machine.

A

...

Only

use

the machine

for

vacuum forming plastic.

It

is

not intended

for

any other purpose.

•

Read

and understand all

of

this user manual.

• This

is

a 'single person operating' machine.

•

Do

not operate the machine until you have been trained

and

are fully conversant with

it

.

II"

Users

of

this machine should complete regular competence tests.

•

Check

your supply voltage

and

frequency. Make sure

it

is

compatible with your machine. Your

machine's electrical specification

is

on the plate on

the

Left hand side.

•

You

must ensure

that

the machine

is

properly earthed

and

fused.

II"

Ifyour machine

is

not

equipped with a moulded mains connector then note

that

:

The

earth wire

is

GREEN

with

a

YELLOW

stripe.

===

The

live wire

is

BROWN

The

neutral wire

is

BLUE

...

Only suitably qualified personnel should make electrical connections

...

Turn

off

the machine and disconnect the power supply when the machine

is

not

in

use

.

.,..

The heater

and

pump on this model are

not

intended

to

be

left running indefinitely.

...

This

machine

is

fitted with a dry running vacuum pump.

Do

not

lubricate.

Do

not

allow any liquid

to

enterthe vacuum system. Ensure

that

moulds are properly sealed

to

prevent ingress

of

dust into

the

vacuum circuit. Severe damage may

be

caused

if

the above

is

not

observed.

...

Note the safety warning labels situated on

the

front

and rear panels. Never remove any warning

labels from the machine.

...

Never remove any panels unless

the

electrical supply

has

been isolated.

.,..

Ensure

that

the area surrounding the machine

is

clean and frequently cleared

of

finished product and

any scrap.

.,..

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 liftingtechniques in order

to

minimise these effects.

Page

3

Safety

Hazards specific

to

this machine.

It

is

vital

that

any person using this machine and

the

person(s) responsible

for

the

health & safety is made fully

aware

of

the

potential hazards

that

could arise

from

the

use and misuse.

1. Electric shock.

This machine

uses

Voltages up

to

240Vac.

NEVER

ATIEMPT

ANY

REPAIR

UNLESS

THE

ELECTRICAL

SUPPLY

DISCONNECTED.

ONLY

SWITCH

ON

WHEN

ALL

COVERS

HAVE

BEEN

REPLACED.

ONLY

A

QUALIFIED

ELECTRICAL

TECHNICIAN

MAY

WORK

ON

ANY

PARTS

CARRYING

MAINS

VOLTAGE

AND

SHOULD

BE

RESPONSIBLE

FOR

ENSURING

THATTHE MACHINE

IS

IN

A

SAFE

CONDITION

BEFORE

ALLOWING

SERVICES

TO

BE

RESTORED.

A 2. Burning.

Parts

of

this machine reach temperatures in excess

of

300°C.

NOTE

THE

'

HOT

SURFACES'

SAFETY

LABELLING

ON

THE

HEATER

& H

EATER

GUARD

.

SPECIAL

PRECAUTIONS

MUST

BE

TAKEN

TO

ENSURE

THAT

ONLY

THE

MACHI

NE

OPERATOR

IS

IN

THE

OPERATING

AREA

DURING

USE.

USE

PERSONAL

PROTECTIVE

EQUIPMENT

SUCH

AS

GLOVES

WHEN

TESTING

THE

HEATED

PLAST

IC,

HANDLING

HOT

VACUUM

FORMED

PARTS,

MANUALLY

ASSISTING

THE

FORMING

PROCESSS

AND

TOUCHING

HOT

SURFACES

.

INFRARED

RADIATION

IS

EMITIED

BY

THE

QUARTZ

HEATERS

,

ENSURE

THAT

ANY

EXPOSURE

TO

T

HIS

TYPE

OF

RADIATION

IS

SHORT

OR

COMPLETELY

AVOIDED

.

WAIT UNTIL

THE

MACHINE

HAS

COOLED

DOWN

BEFORE

SERVICE

WORK

COMMENCES

.

3. Toxic Fume Inhalation.

When plastic sheet

is

heated fumes will be given

off

.

ENSURE

THATTHE MACHINE

IS

POSITIONED

IN

AN

ADEQUATELY

VENTILATED

PLACE.

IT

IS

THE

RESPONSIBILITY

OF

THE

OWNER

OR

DESIGNATED

RESPONSIBLE

PERSON

FOR

HEALTH

AND

SAFETY

TO

ASSESS

THE

RISKS

ASSOCIATED

WITH

ANY

DANGEROUS

FUMES

GIVEN

OFF

AND

TO

DETERMINE

ANY

NECESSARY

PRECAUTIONS

REQUIRED

SUCH

AS

FUME

EXTRACTION

PRIOR

TO

USE

.

4.

Injury

from

Trapping.

CARE

IS

REQUIRED

WHEN

OPERATING

THE

CLAMPING

FRAME

TO

ENSURE

THAT

FINGERS

OR

HANDS

ARE

NOT

TRAPPED

.

KEEP

HANDS

CLEAR

OF

THE

HEATER

RAILS

WHEN

PULLING

THE

HEATER

FORWARDS

.

5. Fire.

RISK

OF

FIRE

AS

A

RESULT

OF

HEAT

AND

PLASTICS

PRESENTS

AN

EMERGENCY

SITUATION.

ENSURE

FIRE

SAFETY

TRAINING

IS

PERFORMED

&

CONTROLLED

.

IT

IS

ESSENTIAL

TO

HAVE

FIREFIGHTING

EQUIPMENT AVAILABLE

AT

OR

NEAR

THE

MACHINE.

USE

DRY

POWDER

(BLUE)

OR

CARBON

DIOXIDE

(BLACK)

FIRE

EXTINGUISHERS.

Page

4

-

Safety

6. Prohibited Uses

DO

NOT

USE

THIS

MACHINE

FOR

ANY

PURPOSES

OTHER

THAN

THE

VACUUM

FORMING

AND

BLOW

MOULDING

OF

PLASTICS

SHEET

.

DO

NOT

USE

THE

HEATER

TO

APPLY

HEAT

TO

ANY

MATERIAL

OTHER

THAN

PLASTIC

SHEET

AS

PART

OF

THE

VACUUM

FORMING

PROCESS

SUCH

AS

:

FOOD

PRODUCTS,

ALL

TYPES

OF

PARTICLES,

POWDER,

DUST,

ALL

TYPES

OF

LIQUID, WOOD,

PAPER,

METALS

AND

ANY

FORMS

OF

COMBUSTABLE

MATERIALS.

DO

NOT

USE

THE

TABLE

MECHANISM

TO

CLAMP

,

COMPRESS,

FOLD

OR

APPLY

FORCE

TO

ANY

ITEM

UNDER

ANY

CIRCUMSTANCES.

DO

NOT

USE

THE

CLAMPING

FRAME

TO

CLAMP

COMPRESS,

FOLD

OR

APPLY

FORCE

TO

ANY

ITEM

OTHER

THAN

THE

CLAMPING

OF

SHEET

PLASTICS

AS

PART

OF

THE

VACUUM

FORMING

PROCESS

.

DO

NOT

USE

THE

TOP

OF

THE

HEATER

OR

TOP

OF

THE

HEATER

GUARD

TO

STACK

PLASTICS

OR

-

OTHER

MATERIALS

.

DO

NOT

USE

THE

MACHINE

TO

STACK

OR

LEAN

ITEMS

AG

INST

THE

SIDES

.

DO

NOT

USE

ANY

OTHER

PART

OF

THE

HEATER

TO

MOVE

THE

HEATER

FORWARDS

AND

BACKWARDS

OTHER

THAN

THE

HEATER

HANDLE

.

-

DO

NOT

USE

OR

MODIFY

THE

ELECTRICAL

POWER

IN

THE

INTERNAL

WIRING

TO

SUPPLY

ANY

OTHER

DEVICE

OR

TO

APPLY

MODIFICATIONS

TO

THE

MACHINE

OR

ITS

FUNCTIONS.

-

THIS

IS

NOT

AN

EXHAUSTIVE

LIST

OF

THE

POSSIBLE

MISSUSE

OF

THIS

MACHINERY.

THE

USE

OF

THIS

MACHINE MUST

BE

ASSESSED,

MONITORED

AND

CONTROLLED

BY

THE

PERSON

RESPONSIBLE

FOR

THE

HEALTH

AND

SAFTEY

IN

THE

ORGANISATION

THAT

OWNS

AND

OPERATES

THIS

MACHINE.

Transportation / Positioning

The

300XQ

will

be

supplied strapped to a Pallet or

in

a crate.

The

machine

may

unpacked

and

placed

on

a

bench,

table or

300XQ

trolley.

Ensure

thatthe structure,

size

and

load

bearing

capacity

of

the

bench

or table

is

sufficient for the

machine

weight. Aminimum

of

2

persons

are

required to liftthe

machine.

In

the

case

of

the

300XQ

trolley,

ensure

that the 2

machine

retaining

screws

are

fitted to the

unde

r

side

ofthe trolley I Machine.

Noise emissions

Noise emissions on

the

Formech 300XQ are

less

than 70dB(A).

Machine storage

The Formech 300XQ must

be

stored in a

dry

environment.

Page

5

lntrodudion and initial assembly

The

Formech 300XQ

is

a highly versatile, manually operated Vacuum Forming Machine

that

will produce high

definition mouldings in up

to

6mm thick material.

It

is

intended

for

use

only

for

the Vacuum forming

of

plastics

components and

for

the blow moulding

of

heated plastics.

Your Formech machine

is

supplied with

lx

Electrical cable

lx

Installation/Operations/Repair

Manual

lx

Table lever (a)

(•)The 300XQ machine

is

fully assembled except

for

the table lever.

lx

EC

Certificate

of

conformity

lx

Table mesh

ENSURE

THAT

THE

TABLE

LEVER

IS

TIGHTLY

SCREWED

INTO

THE

CRANK

MECHANISM

ON

THE

RIGHT

HANDSIDE

OF

THE

MACHINE.

IF

OPERATED

WITH

THE

LEVER

LOOSENED

YOU

MAY

DAMAGE

THE

CRANK

OR

THE

HANDLE.

--

Page

6

._

......

_

..

-

Optional

extras

The following items

can

be purchased

for

your 300XQ vacuum forming machine

1. Machine trolley with castors

2.

Reducing windows 3. Blow mould

window

4.

Service kit

1. The Formech machine trolley allows you

to

easily move your 300XQ machine. The 2 locking castors assure

the trolley remains in position all the time. Underneath there

is

also

space

to

store plastic material

and

moulds.

2.

Formech have available a standard

sizes

of

reducing plates.

This

reducing plate allows

the

use

of

plastic

size

254mm x 228mm. Formech

can

also produce special

size

reducing windows. For more information please

contact our

sales

department.

3.

You

can

use

your vacuum forming machine

to

do blow moulding by fitting a special circular reducing

window

to

your machine. The maximum diameter you will get on the 300XQ

is

300mm.

For

more information

please contact our

sales

department.

4.

It

is

unlikely

that

you will need

to

service

or

repair your machine

for

many years provided you

follow

the

maintenance information contained in this manual; howeverthe table and clamp

seals

, which are considered

to

be

consumable items, will need

to

be

replaced depending on the

usage

of

the machine. Therefore this kit

contains

the

essential consumables

(seals

and

pump filter)

to

ensure agood performance

of

your machine

year on year.

Page

7

General Arrangement

ELECTRICAL

SPEC

IF

IC

ATIO

N

Standard Voltage: 220-240

Standard fr

eq

uency: 50/60!-lz

Standard Max Power: 2.3Kw

1.

Spech:a

tion plate

2. Power inlet receptade

3. Power switch

00

/

0FF

4. Clampframe

5. Matera! damps

6. Heater

Bo

x

7. Vacuum\pressurevalve

8. Table

le

v

a-

9. Control

pe11el

10. Pump switch

ON

I O

FF

1

1.

Ar

output

MECHANICA

L

SPEO

RCATI

ON

DO

NOT

CONNECT

AIR

SUPPLY

HERE

Standard material size 450mm x300mm (18'' x 12'')

Maximumforming area 430mm x 280mm (

16

.9" x11.02'

')

Maximumdepth

cl

ctaw 185

mm

(6 7/8'')

Overall

wdth

640mm (25 1/4

")

Overall height 530mm (

21

'

')

Overall length 1

OOOmm

(

39

31

8'

')

W

ei

ght 65kg (1

451bs)

1. Specification Plate. This states

the

essential machine data &

CE

marking.

2.

Power Inlet receptacle. The machine

is

supplied complete with a power cable

that

pl

ugs

into

this receptacle

and then into a suitable power socket.

If

your

machine

is

a special voltage

or

frequency then

it

may be

supplied

with

a lead

not

terminated

into

a mains plug.

See

Safety section at

the

beginning

of

this manual.

Note

the

safety labelling.

3. Power Switch ON/OFF. This

is

the main switch. When in

the

OFF

position power

is

cut

to

all functions.

Before commencing any repair work always remove

the

mains lead

from

the

Power Inlet Receptacle.

4.

Clamp Frame.

This

holds

the

plastic material in position during

the

fo

rming and release processes.

5.

Material

Clamps. These clamps fix

the

Clamp Frame firmly down. After placing

the

plastic under

the

clamp

frame

the

material clamps are adjusted bytightening

or

loosening

the

orange nutlets.

The

levers are pulled up

until they are fully over-centre. Adjustment may only be carried

out

while

not

under pressure. The rear

of

the

clamp frame

is

selfadjusting.

6. Heater Box. This carries

the

heating elements and

is

drawn forward by pulling

the

centrally mounted

handle.

7. Vacuum/Pressure Valve. When

the

vacuum pump

is

running

th

is

va

l

ve

switches between removing air

from between the mould and moulding duringforming (vacuum) and introducing air between

the

mould and

moulding

for

finished part release (pressure).

Page

8

-

General Arrangement

<cont.)

8. Table Lever. When pulled towards you the table will rise

to

the upper

limit

. A

further

application

of

pressure will lock the table in this position. During forming

the

table complete

with

mould

is

lifted into the

hot

plastic and locked in place

to

ensure a good vacuum

seal.

At the end

of

the cycle the table

is

returned

to

the

lower position by pushing the handle back and away.

NOTE

: A mechanical interlock designed

to

prevent a mould being raised into the heating elements stops the

table being raised unless the heater box

is

fully back.

9. Control Panel.

See

below control panel layout.

10. Vacuum Pump ON/OFF switch.

This

turns the vacuum pump on and

off

. The vacuum pump evacuates the

air between

the

plastic sheet and the mould. It also provides pressure

to

release the finished moulding

from

the

mould.

11.

Air

pressure outlet. When the vacuum pump

is

running, the pressure

is

diverted

to

this outlet. This

can

be

used

to

supply or run other equipment when not being

used

for

vacuum forming. Do

not

block this

outlet

or

attempt

to

connect

air

supply. This machine

DOES

NOT require air supply.

- 4''

,

~

l

llll

l0

• •

_

...

0

15

12. Heater Zone layout

15

.

Hea

ter timer

13. Heaterstandby level contr

ol

16. Vacuum Gauge

14. Zone powerlevel controls

12. Heater Zone layout. Pictogram showing the corresponding zone layout

of

the quartz heater zones.

13. Heater Standby Level (Power Saving Feature). The 300XQ

is

supplied with fast acting heating elements.

This means

that

when

the

heater

is

not

actually heating plastic

the

power

can

be

turned down.

As

the heater

is

moved

from

the rear position the elements begin

to

heat up

to

the set power level.

For this feature

to

work effectively the power level at rest

or

standby must be set

to

approx.

30%.

For

continuous usage the standby level may

be

set lower. For infrequent usage

it

may be required

for

the standby

level

to

be

set higher. For non-time critical

uses

the standby level

can

be

set at about

10%.

Although the

plastic may take a

few

extra seconds

to

heat, the overall power saving will

be

substantial

Safety

Notice

:

It

is

advisable

to

monitor

the

heating stage

by

making

frequent

observations.

Never leave

the

machine unattended when actively heating plastic.

14. Heater Zone Controls. The 300XQ heater

is

divided into 4 zones

as

shown by the diagram (12)

on

the

control panel. This

is

to

allow the user maximum flexibility especially when producing mouldings from difficult

moulds

or

difficult plastics.

It

is

usual

to

turn

the centre zone 1 down slightly because

it

gains extra heat from

the other zones surrounding it. The back zone 3 also tends

to

stay

hotter

than

the

front

zone 4 because the

rear

of

the machine

is

heated

by

the heater when

it

is

not heating plastic. A key feature

of

quartz heating

is

Page

9

the response time

for

changing

to

different power levels. The zone controllers are highly accurate and keep

the element power level

within

1%

of

the

requested setting. Beginners

to

vacuum forming will quickly become

accustomed

to

setting

the

zone controls

for

best results.

15. Digital

Timer

. When producing a quantity

of

mouldings using

the

same mould and plastic

the

heating

ti

me

will be nearly constant

for

each one. In this

case

the

timer

can

be used. Record

the

heating

time

for

the first

mouldingthen set

the

timer

(in seconds) using

the

UP/

DOWN

buttons

the

buttons. When

the

heater

is

pulled

forward

the

timer

counts down from

the

set time

and

sounds a buzzer when zero

is

reached. The heater is

then pushed back. The set

time

is

stored until

it

is

altered.

If

you don't

want

to

use the timer, set

the

time to

zero.

The

timer

has

built in safety features.

If

the

heater

is

forward

fo

r more than 2 minutes

after

the

timer

has

completed

the

set

time

the

heater will switch

to

the standby setting.

If

the

heater

is

not

returned

to

the

standby posi

tion

aftera

further

2 minutes then

the

heater will

turn

off

all power

to

the

heating elements.

16. Vacuum Gauge. This

is

situated on

the

top

RHS

of

the

front

panel and gives indication

of

the

vacuum level

achieved

at

the

table mould area during moulding. It

is

usual

to

expect approx 22"Hg I -750mbar

of

vacuum. If

such levels are

not

achieved check your mould I table configuration & clamp I plastic

seal

ing.

Reducing Windows

Reducing windows allow

the

use

of

smaller sheet material

for

smaller mouldings. Reducing windows all

ow

for

better

sheet utilisation.

To

fit

the

reducing wi

ndow

.

1. Lift

the

clamp frame.

2.

Place

the lower reducing

window

plate on to

the top

frame aperture

so

that

the corn

er

locating

screws are

al

igned.

3.

Place

the

top

reducing window plate on

the

underside

of

the

clamp frame. There are folded sections

on

the

front

and rear.

The

rear edge

has

the larger return and wraps completely around

the

clamp

frame bar.The

front

fold

is

smaller and returns against

the

front

clamp frame bar. The fixing bolt

is

fitted

through

the

clamp frame bar and reducing plate and secured using

the

fixing n

ut

..

See

diagram

below

of

side view

of

the

top

plate

fitting

.

Rea

r

of

cl

amp

f

rame

Fr

on

t

Si

ide

v

tew

4.

Close

the clamp frame.

Check

alignment

oftop

and

bottom

plate. Fit

the

required plastic

mater

i

al

on

the

sealed lower reducing plate. The material toggle clamps will need adjusting so

that

the

clamp

frame

can

be

locked

to

achieve

the

necessary clamping pressur

e.

Page

10

-

FORMTECH 300XQ Manuale di servizio

Manuali Macchina rilegatrice popolari di altre marche