1372SA. Large Format Vacuum Forming Machine. Installation, Operating and Service Manual

Transcription

1 Large Format Vacuum Forming Machine. 1372SA Installation, Operating and Service Manual For Parts, Service & Technical Assistance Telephone: +44 (0) Fax: +44 (0)

2 Table Of Content Safety 4 Introduction 8 General arrangement 9 Specifications 11 Foreword 11 Specifications 11 Noise emissions 11 Machine storage 11 Machine transportation, lifting and moving 11 Installation 12 Electrical connection 12 Important notice on 3 phase & Neutral connections 12 Phase Connections / Motor Rotation 12 Pneumatic connection 13 Assembly of the control POD 13 Counterbalance arms and weights 13 Cooling System 14 Using the Cooling System 14 Introduction 15 Operation - Main Menu Functions 16 Operation - Manual Functions 17 Getting started 17 Manual Control Functions 17 Emergency Stop 17 Table buttons (on front machine panel) 18 Manual Clamping 18 Control POD Manual operation Screen 19 Manual Setup 21 Operating Procedure 23 Operation - Setup functions for semi automatic use 25 Main Screen 25 Settings 25 Heating zones 27 Standby function 28 Set heat time 28 Set pre-stretch time 28 Set vacuum time 29 Set fan time 29 Set release time 30 Set table down time 30 Save or Exit button 31 Memory screen 31

3 Table Of Content (continuation) Operation - Semi-automatic cycle 32 Heater Settings SA - Zone Layout SA Heater element power arrangement 34 Heating Zone Control and Adjustment 34 Other Controls and user adjustments 35 Table Speed adjustment 35 Table Height Adjustment 36 Clamp Frame rear spring adjustment 36 Clamp Frame speed adjustment 36 Front clamp limit switch adjustment 37 Clamp frame Jacking bars - Front and Rear 37 Counterweight adjustment - loading and unloading 37 Touch screen control POD position 37 Heater motor speed 37 Fixing mould tools 38 Fault diagnostics/maintenance 39 Electrical 39 Typical fault scenarios 39 Heater 40 Replacing a heating element 40 Auto-Levelling system 45 Vacuum 46 Vacuum system 46 Pneumatics 48 Table Cylinder Maintenance 48 General lubrication 49 Clamp & Table Seals 49 To replace a damaged or worn seal 49 Cleaning 49 Lubrication 50 Panel Seals 50 Service Support 50 Forming Difficulties 51 Warranty 52 Clamp Seals 52 Heating elements 52 Vacuum system 52 Electrical Circuit information 53 EC Certificate 63

4 Safety 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 local regulations and carried out by a suitably qualified technician. THIS MACHINE MUST BE EARTHED IN ACCORDANCE WITH LOCAL REGULATIONS. 2) Ensure that the pneumatic air supply 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 and blow moulding of 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 waste. 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

5 Safety HEALTH & 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. 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. ONLY A QUALIFIED ELECTRICAL TECHNICIAN MAY WORK ON ANY PARTS CARRYING MAINS VOLTAGE AND SHOULD BE RESPONSIBLE FOR ENSURING THAT THE MACHINE IS IN A SAFE CONDITION BEFORE ALLOWING SERVICES TO BE RESTORED. 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. USE PERSONAL PROTECTIVE EQUIPMENT SUCH AS GLOVES WHEN TESTING THE HEATED PLASTIC, HANDLING HOT VACUUM FORMED PARTS, MANUALLY ASSISTING THE FORMING PROCESSS AND TOUCHING HOT SURFACES. INFRARED RADIATION IS EMITTED BY THE QUARTZ HEATERS, ENSURE THAT ANY EXPOSURE TO THIS TYPE OF RADIATION IS SHORT OR COMPLETELY AVOIDED. 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 THE 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 AND THE ELECTRIC 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 OR SAFETY RELATED CONTROL SYSTEM SUCH AS THE 2 HANDED CONTROL SYSTEM. 5

6 Safety HEALTH & SAFETY - Hazards specific to this machine. 6. Injury from Trapping. There is a risk of trapping fingers and hands when loading mould tools. Ensure appropriate care is taken to prevent trapping and use suitable personal protection. 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. 7. Lifting, Reaching and Stretching. TAKE CARE WITH LIFTING REACHING AND STRETCHING WHEN PERFORMING THE FOLLOWING ACTIVITIES: -Operating the manual heater, the loading of materials and unloading of plastic formings. -Applying manual assistance to formings during vacuum. -Drilling holes and trimming of mouldings on the machine after forming. -The fitting and loading of mould tools. -Loading and fitting of reducing plates and frames. -Fitting and adjustment of Fans. -Replacement and maintenance of top frame and table seals. ENSURE THAT LOCAL LIFTING AND HANDLING PROCEDURES ARE APPLIED AND MONITORED BY A PERSON RESPONSIBLE FOR HEALTH AND SAFETY. 8. Fire. The sheet auto-levelling system allows the level of heated plastic to be kept constant. There is a risk that failure of the level sensors due to misuse of heaters OR the setting of the compressed air supply to a level that exceeds the operating pressure of pneumatics valve and the machine specification may cause the plastic to be blown into the heaters and to be ignited. Periodically monitor and check the condition of the infrared beam sensors. ENSURE THE COMPRESSED AIR SUPPLY IS SET TO THE RECOMMENDED LEVEL AND ONLY USE THE HEATER FOR THE HEATING OF VACUUM FORMING PLASTIC MATERIALS. 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. 9. Airborne Particles. Particles present in the working area may become airborne during the use of the fan cooling system, when using an airline to blow onto plastics and when the release function is operated without tooling fitted. ENSURE THAT THE DUST, PARTICLES AND DEBRIS IN THE WORKING AREA ARE KEPT TO A MINIMUM. ENSURE THAT SUITABLE EYE PROTECTION IS WORN. 10. Working at Height. When installing the fan cooling system, it is necessary to work at an appropriate height. Ensure that adequate safety precautions are taken to prevent falling from height and that suitable, stable and secure equipment is used to support your weight when working at height. Ensure that you DO NOT work on your own when working at height. ENSURE THAT LOCAL LIFTING HANDLING AND HIGH LEVEL WORKING PROCEDURES ARE APPLIED AND MONITORED BY A PERSON RESPONSIBLE FOR HEALTH AND SAFETY. 6

7 Safety HEALTH & SAFETY - Hazards specific to this machine. 11. 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 RELEASE TABLE AIR FUNCTION TO APPLY PRESSURE FOR ANY OTHER MEANS OTHER THAN TO RELEASE THE MOULDING FROM A FITTED MOULD TOOL. DO NOT USE THE TABLE VACUUM PORT TO SUPPLY VACUUM FOR ANY OTHER MEANS OTHER THAN TO APPLY VACUUM UNDER A MOULD TOOL AS PART OF THE VACUUM FORMING PROCESS DO NOT ALLOW OTHER PERSONS WITHIN 1 METRE (39 INCHES) OF THE TABLE / APERTURE TRAP POINT WHEN OPERATING THE TABLE USING THE TWO HANDED CONTROL TABLE LIFT FUNCTION. DO NOT BLOCK THE PUMP EXHAUST PORT ON THE REAR OF THE MACHINE AND DO NOT USE THIS PRESSURE OUTLET TO APPLY PRESSURE FOR ANY OTHER PURPOSE. DO NOT USE THE TOP OF THE HEATER OR TOP OF THE HEATER GUARD TO STACK PLASTICS OR OTHER MATERIALS. DO NOT USE THE UNDERSIDE OF THE REAR OF THE MACHINE TO STORE ANY ITEM(S). DO NOT USE THE MACHINE TO STACK OR LEAN ITEMS AGAINST THE SIDES. DO NOT USE THE FAN OUTPUTS TO APPLY AIRFLOW FOR ANY OTHER PURPOSE OTHER THAN THE COOLING OF VACUUM FORMINGS AS PART OF THE VACUUM FORMING OR BLOW MOULDING PROCESS. DO NOT OBSTRUCT THE HEATER TRANSORT WITH ANY ITEM OR USE THE TRANSPORT WHEELS TO CUT OR FORM ANY ITEM OR MATERIAL. DO NOT USE ANY OTHER PART OF THE HEATER TO MOVE THE HEATER FORWARDS AND BACKWARDS OTHER THAN THE HEATER HANDLE. DO NOT USE THE FAN GANTRY TO HANG ANY ITEM. DO NOT MOUNT THE FAN POSTS ON THE UNDER SIDE OF THE FAN GANTRY DO NOT REMOVE THE SIDE PANELS OF THIS MACHINE TO USE THE PNEUMATIC CYLINDER TO CUT, COMPRESS, BEND OR FORM ANY ITEM. DO NOT USE OR MODIFY THE ELECTRICAL POWER IN THE CONTROL PANEL 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. THIS LIST IS WHAT IS CONSIDERED TO BE FORESEEABLE MISSUSE. 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. 7

8 Introduction The Formech 1372SA 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. The Formech 1372SA incorporates the following features: Easy to use graphical touch screen with single screen forming cycle operation and 20 job storage facility. Powerful quartz heaters PLC controlled in 15 heating zones. Flexible semi-automatic operation. Heater power level standby feature allowing energy saving when heater is in rear position. Heater safety shutoff after idle period A powerful filtered dry rotary vane vacuum pump. Reliable and robust PLC control system & touch screen. Vacuum & Pressure gauge indication. 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 blown into the chamber beneath the plastic keeping the sheet level until it is ready to be formed. A powerful compressed air blow pre-stretch facility. A pneumatically powered scissor table incorporating 2 handed manual control allowing easy and safe use of heavy moulds. Table speed can be adjusted by externally mounted table speed controls. An easily adjustable table height facility to assist performance with shallow mouldings. A powerful compressed air blow facility to release the moulding from the tool. The 1372SA is ideal for prototype development work whilst also quite capable of small and large production runs. 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. Optional powerful fan cooling system. This manual is the original user instructions for the Formech 1372SA. It informs the user on machine safety, assembly, operation and maintenance. It also provides an introduction into vacuum forming with some useful advice 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 and about section of the Formech web page. 8

9 General arrangement Heater 2- Pneumatic Clamp Handles 3- Operation POD 4- Table Up control buttons 5- Table adjustment (depth of draw) 6- Heater Guard 7- Counter balance weights 8- Self-adjusting clamp springs 9- Control box with main switch 10- Heater rear supports

10 General arrangement Machine Footprint 2140mm 2000mm 10

11 Specifications Foreword Please read this manual thoroughly before attempting to install or use this 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. Specifications 1372SA Forming area: 1330mm x 620mm. Depth without POD: 1820mm. Depth with POD: 2000mm Sheet Size: Nominal 1372mm x 660mm Material thickness 0.25mm min. 6.0mm max Electrical Power - 17kW - Supply V, 5 wire, 3 phase + Neutral + earth, 50Hz Power - 17kW - Supply V, 4 wire, 3 phase + earth, 60Hz (North America) Width: 2000mm Length:2140mm Height:1320mm Height with fans: 2420mm Weight: 600Kg Noise emissions Noise emissions on the Formech 1372SA are less than 70dB(A). Machine storage The Formech 1372SA must be stored in a dry environment. If the machine is not used for a long period of time, run the pump periodically (once a month). Machine transportation, lifting and moving The Formech 1372SA is prepared for transportation with the heater secured forwards with counterweights and accessories situated at the front of the machine where possible. The weight of the packaged machine is towards the front. Before lifting, remove all separate assemblies and leave the heater fixed in its position until positioning at its operating site. Remove packaging where it assists with lifting and moving. The machine must be lifted from the front taking particular care to avoid damage to the front clamping frame and control pod. The centre of gravity is at a point centre - rear of the main cabinet when viewed from the front. Ensure lifting forks pass through to the rear of the main cabinet and to the rear frame. Ensure that local lifting and handling procedures are applied and monitored by a person responsible for health and safety. 11

12 Installation 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 (750mm) 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 V Three phase supply Using 3 phases, Neutral and Earth connection STAR configuration. 3P, N & E 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. Important notice on 3 phase & Neutral connections To prevent damage of components it is highly important to check that the three phase and neutral connections are correct. The machine colours for wiring are as follows: Brown L1 - Phase 1 Black L2 - Phase 2 Grey L3 - Phase 3 Blue Neutral Green/Yellow Earth or Ground After making connections to the isolator switch in the rear cabinet it is essential to verify that the phases and neutral connections are terminated correctly. The three phases must be connected to the connections L1, L2 & L3. The Blue neutral connections must be connected to the terminal labelled N. Verify these connections using a volt-meter / multi-meter by measuring the voltage potential between the Neutral and each phase in turn. The voltage between each phase and the neutral should measure V ac. Once this is confirmed the Electrical box cover may be fitted and the isolator switch turned on. Phase Connections / Motor Rotation For all electrical connections the pump rotation direction is important. After switching the machine on press the Vacuum button on the operation screen and check that vacuum is present at the hole in the centre of the table. If there is no vacuum or if pressure is present then reverse 2 of the phase connections. THIS MACHINE MUST BE EARTHED IN ACCORDANCE WITH LOCAL REGULATIONS 12

13 Installation The 1372SA must be installed and commissioned by a Formech qualified technician. Pneumatic connection If the air supply is insufficient the performance of the machine will be compromised. The connection to the machine should be via a lockable shut off valve. Ensure that the pneumatic air supply is regulated to 6 BAR or less and is properly filtered & lubricated using good quality airline oil. A competent person must make compressed air connections. If flexible hoses are used it is strongly advised that they are of Nylon, canvas or wire reinforced rubber and suitably rated for pressure and temperature. The connection hose size should be 12mm diameter.threaded fittings are BSP. Maximum airline pressure must not exceed 5BAR or 80 PSI. The effectiveness of the prestretch and autolevel functions rely on a large volume of air being delivered rapidly to the machine. For this reason an air reservoir should be sited as close to the machine as practical. If this is not possible then large bore pipes can be used to prevent pressure drop when the above functions are used. Assembly of the control POD Where the 1372SA is delivered in a packaging crate, the control pod may be rotated or removed. Remove the three fixing screws from their fixing point at the front RHS corner of the machine, rotate the POD and refit the 3 screws to allow the POD to be at a suitable angle. Ensure the rubber seal is located in the POD stand and the fixings are tight. DO NOT LEAN ON THE POD. Counterbalance arms and weights The counterbalance arm assembly is permanently attached to the clamp. Either 5 or 6 counterbalance weights are fitted to the arms depending on the weight of a reducing frame, if fitted. These need to be set in position to balance the clamp frame. Remove the split pin and washer at the end of each arm and slide the weight towards the front of the machine and lock in place with the screw fitted to each weight. They are easily adjusted by loosening the screw with a 13mm spanner or socket. ENSURE SCREWS ARE LOCKED TIGHT. Adjustment may be required where a reducing window is fitted. Adjust the weights so that the clamp frame is balance. The clamp frame may need to be lifted to fit the RHS weight. Set the weights so that the clamping frame is balanced at a suitable height. COUNTERWEIGHTS ARE HEAVY ITEMS AND HENCE CARE MUST BE TAKEN TO PREVENT TRAPPING OF FINGERS. TAKE CARE WHEN ASSEMBLING, LOADING AND UNLOADING COUNTERWEIGHT. HEAVY ITEMS CAN CAUSE CRUSHING IF MISSHANDLED, MISSUSED OR IF DROPPED. WHEN LOADING AND UNLOADING COUNTERWEIGHTS ALWAYS ENSURE THE END STOP LOCKING SPLIT PIN AND WASHER IS REPLACED AT THE END OF THE COUNTERWEIGHT ARM. 13

14 Installation 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 top of the gantry sides with the four nuts and bolts supplied. The fan mounting posts should be attached to the cross member so that the fan can be positioned behind the cross member directing the fan draft forward and 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. Mounting of the fans is a 2 person operation, precautions must be taken when lifting and working at heights. 4 - Adjust the fan unit to the required position and tighten all the grub screws and lock nuts. Using the Cooling System The corresponding FAN button on the touch screen can operate the cooling fan at the appropriate time to cool the moulding. The button changes colour when operated ON/OFF. It is worth considering the position of the fan mounting to achieve good and consistent results with different mouldings. It is essential to read and fully understand all the information in this manual relating to safety and the Safety Hazards specific to this machine before installing and operating. Operating procedures for this machine must be assessed, monitored and controlled by the person responsible for health and safety. 14

15 Introduction The 1372SA is a large sheet fed vacuum forming machine suitable for forming a wide variety of plastic materials. It has been designed with operating simplicity high on the list of priorities. Operators who have previously used vacuum forming machines will quickly become familiar with the userfriendly controller programming. Those starting out in plastic moulding will find the 1372SA more forgiving than most of its counterparts. The absence of full guarding on the semi-auto version means that the forming area is accessible from both the front and sides of the machine. This enables close inspection of the product being produced and allows for correction during the cycle. Whether required for long or short production batches or for prototyping or sampling the 1372SA adapts quickly to most needs. All of the systems used on the 1372SA have been tested, modified and refined. The result being reliability over a long period. The Formech 1372SA uses the reliable and robust Mitsubishi FX3G PLC with GOT Touch screen user interface. Formech have produced high quality functional graphic software to give an easy to use, flexible and versatile Thermoforming machine for all forms of industrial and commercial use. The 1372SA Software provides for both manual and semi-automatic functionality of the vacuum forming process. The following section explains the 1372SA control functions. 1. Main menu functions. 2. Manual Operation, Heater Settings and the Vacuum Forming Process. 3. Set up and use of the Semi-Automatic Operation. 15

16 Operation - Main Menu Functions Powering up Ensure the Emergency stop button is latched out. Turn on the mains isolator at the control panel at the rear of the machine. The main menu will be shown as below. MAIN SCREEN The Main Menu shows the options. Button descriptions are below. On machine start up default settings are loaded for the heater zones to allow for manual operation. Main screen controls New / Edit Creates a new program or modify an existing one. Manual mode Operate the machine with each action of the machine being activated by the operator. Semi automatic mode Operate the machine by selecting a stored program from the memory. The machine will operate automatically apart from the Table UP action which is activated by the operator.? Heater Default heater settings are pre-programmed for manual operation. Press this button to activate the heater. The heater must be ON to use the machine in manual or semi-automatic mode. The heater can also be switched off during machine or tooling set up. Question mark The question mark icon can be pressed at any time for an explanation of each of the icons 16

17 Operation - Manual Functions Getting started On the main menu screen. Turn the Heater ON Press the Manual Button The Manual Operation Screen will open Manual Control Functions The following section describes the manual controls of the 1372SA. Operate all of these controls independently to ensure you are fully familiar with how the machine operates and how each action behaves. There are three sets of controls: 1. The Control POD and touch screen. 2. The Table UP buttons - Front panel. 3. The Pneumatic Clamp Triggers. Emergency Stop Touch screen Clamp release button Pressure gauge Vacuum gauge Emergency Stop This momentary action latching button cuts the power to all outputs when pressed. The following message shows on the screen. The button will need to be manually unlatched to reset for normal operations to continue. Only use this button in emergency situations. 17

18 Operation - Manual Functions Table buttons (on front machine panel). To bring the table up, press and hold both the table buttons simultaneously (within 500msec). The table will rise to its top position. If the action of either button is stopped, the table will stop and the action must be repeated to continue. To send the table down, press the table down icon on the touch screen and hold down until the table reaches the bottom of its travel. To jog the table down, press the icon momentarily. Table buttons Manual Clamping Hold the clamp handles one in each hand with fingers against the triggers on the underside of each handle. Check there is no obstruction between the clamp frame and the top frame. Lower the clamp frame so that the limit switch of the RHS handle is pressed. Squeeze both clamp triggers simultaneously (within 500msec) to activate the clamping mechanism. The clamp will pull down against the top frame. To release the clamp press the Clamp Release button located on the LHS of the control POD. Clamp Frame Handles 18

19 Operation - Manual Functions Control POD Manual operation Screen Press the Manual Button on the main menu screen The Manual Operation Screen will open as shown. The meaning and operation of the buttons on this screen are shown below. Following this is a full description of the vacuum forming process. The screen icons are designed to be followed round in a clockwise direction, starting with the heaters (top left) and ending with the Table Down Button Auto-level This button enables the auto-level feature. If the plastic is sagging and not being heated evenly then the autolevel feature may be used to keep the plastic level while the heater is forward and until the heater is fully back. Heater Zone settings This Button allows direct adjustment of the heater zones whilst in the manual screen. Heater Drive This icon controls the movement of the heater. The direction of heater movement is reversed each time the button is pressed. Pre-stretch To inflate the plastic before moulding; press the Pre-stretch icon. This feature is particularly useful if the mould is high because it keeps the plastic at a more even thickness throughout the moulding. Prestretch may be used as the table is rising to keep the bubble inflated. Vacuum The vacuum icon is used to apply vacuum to the table. The vacuum tank is continually evacuated by the vacuum pump. The air is evacuated by the vacuum tank combined with the vacuum pump. In manual mode the timer counts up. This button latches ON when pressed. Press again to turn OFF. Fans Pressing the fan icon will turn the cooling fans ON. Press again to turn OFF. In manual mode the timer counts up. 19

20 Operation - Manual Functions TABLE DOWN FINISH Release The release icon is used to blow compressed air between the mould and the finished moulding. Too long a release may distort the moulding. This is a momentary HOLD TO RUN button. Table Down This Button drives the table down when pressed. This is a momentary HOLD TO RUN button and can be used to lower the table is short steps to gently assist with releasing the mounlding without damage if required. Finish This Button returns to the main menu. 20

21 Operation - Manual Functions Manual Setup Select the Manual icon on the main screen. The heater power for manual mode defaults to values of approximately 70%. The standby level is 50%. The heaters are controlled by the PLC system to vary the output of individual zones as displayed on the touch screen. Allow minutes for the heaters to reach operating temperature before attempting to run any mouldings. To change the heating zone settings press the heat zones settings button on the manual operation screen. The individual zones may be set up to provide an even spread of heat. To achieve the best results set the inner zones lower than the outer zones and remember that the rear of the heater will always run hotter than the front. Having set the heaters, slight adjustments may have to be made depending on the mould design, plastic type etc. We recommend that initially all zones are set to 70% power. This will then allow the operator to increase or decrease individual zones as required. There are 15 heating zones on the 1372SA machine Z1 to Z15. Under each Zone number the actual percentage of heat is displayed. Press on a zones to change the set value. The following screen opens. When one of the zones is selected, it will take you to the SET ZONE HEAT LEVEL % screen. All you have to do is to select the most appropriate % for a particular zone. You will then be taken back to the 15 heating ZONE screen to select the other zones. 21

22 Operating - Manual functions Basic heating operation - Manual mode Note: This operation was done with a 2mm HIPS plastic sheet. Turn the isolator switch at the rear of the machine to the ON position. Using the touch screen on the home screen, turn the heater ON. It usually takes between 15/20 minutes for the heaters to reach the operating temperature. Press the two table up buttons simultaneously and hold until the table is fully raised. Raise the pneumatic clamp and place your mould onto the table. Press the table down icon to drive the table into the lower position. Place the plastic over the forming area and ensure the material covers the top frame seal completely. 22

23 Operating Procedure Basic heating operation - Manual mode (continuation) Once the clamp frame is over the plastic, squeeze both clamp triggers simultaneously as described on page 18. Press the heater icon as shown and the heater will be driven forward over the plastic and stop automatically when the front limit switch is trigerred. (1) If the plastic is sagging and not being heated evenly then switch the autolevel feature as shown. Once the plastic is at the correct temperature for moulding, then send the heater to the back position by pressing the heater button. If the moulding is quite high, it may be necessary to pre-stretch the plastic before moulding takes place. To do this, press the pre-stretch button as shown when the heater is in the back position. Press both table buttons simultaneously to raise the mould into the plastic. (1) The heating of the plastic sheet may be checked by pressing the heater icon to send the heaters to the rear momentarily as described earlier. 23

24 Operating Procedure Basic heating operation (continutation) Press the vacuum button to apply vacuum to the table. At the appropriate time, turn on the fans to start the plastic cooling process. Once the plastic has cooled sufficiently, press the release icon to blow the moulding off the tool. Once released, the moulding is now complete and the table may be lowered. Press the table down icon and ensure the moulding has released from the mould tool. Ensure the table has reached its lower position. Release the clamp frame to remove the moulding for inspection. 24

25 Operation - Setup functions for semi automatic use Main Screen To set up the PLC for a semi automated cycle ensure the heater is in the back position and the clamp frame is unclamped. Press the NEW/EDIT button on the Main screen. This allows you to choose to edit an existing job or create a new job memory. Press NEW to open the setting screen. Settings The name of the job memory being edited is shown Blank if setting a new job. The icons on the SETTINGS screen allow the time parameters to be programmed. Press each of the coloured icons in turn and enter the desired timings and settings. Button functions are summarised below. Further details are shown in the settings section. Heater Press the Heater icon to set the heating time. Enter the number of seconds required. Release Press this icon to set the pre-stretch time. Enter the number of time required. Time can be set to 1/100th of a second. Vacuum The vacuum icon allows you to enter the time that the vacuum pump stays on. This time starts from the point that the table reaches the top position. Fans and fan delay If the fan delay is set to 10 seconds then the fans will start 10 seconds after the point that the table reaches the top position. The fans will run for the set run time allowing the vacuum to pull the sheet in tightly around the tool before cooling the part. 25

26 Operation - Setup functions for semi automatic use Table down delay The table down delay time allows adjustment of the moment that the table descends. For most purposes use the same time as the release time. If additional release air is required as the table descends then reduce the table delay time whilst keeping the release time greater. Release Press the release icon to set the time for air to blow the formed plastic off the mould. Enter the number of seconds required. Time can be set to 1/100th of a second. Auto Level Press this icon to activate the auto-level. This allows compressed to blown under the sheet during the heating process so that the sheet remains horizontal to the heaters at all times for even heating. Zones This icon allows you to adjust all of the 15 heater zones on the 1372SA to the desired percentage of heat. Adjustable by increments of 5%. Standby The standby feature allows you to reduce the temperature of the quartz elements when they are not required in the rear position. As soon as the heaters come forward they very quickly power up to the correct temperature. 26

27 Operation - Setup functions for semi automatic use On the SETTINGS screen you will need to enter times and settings for each of the functions of the machine represented by the icons. When you select the ZONES button, the heater ZONES screen will be displayed as shown below. Heating zones There are 15 heating zones on the 1372SA machine Z1 to Z15. Under each Zone number the actual percentage of heat is displayed. When one of the zones is selected, it will take you to the SET ZONE HEAT LEVEL % screen. All you have to do is to select the most appropriate % for a particular zone. You will then be taken back to the 15 heating ZONE screen to select the other zones. 27

28 Operation - Setup functions for semi automatic use Standby function When the STANDBY button is selected from the SETTINGS screen it allows you to adjust the percentage of heat. We recommend 50% Standby for the heaters in the STANDBY rear position. You will then be taken back to the SETTINGS screen. Set heat time When the HEAT Button is selected, it allows you to adjust the time that the heaters come forward over the material. Press the set value in the RED Box and use the digital keypad to set a time. When a new time is entered in the keypad press ENT Set pre-stretch time When the PRE-STRETCH is button selected, it allows you to adjust the time that the pre-stretch is activated. Press the set value in the RED Box and use the digital keypad to set a time. When a new time is entered in the keypad press ENT. Pre-stretch times can be set to 0.01 Secs. 28

29 Operation - Setup functions for semi automatic use Set vacuum time When the VACUUM button is selected, it allows you to adjust the time that the vacuum is activated. Press the set value in the RED Box and use the digital keypad to set a time. When a new time is entered in the keypad press ENT. Set fan time When the FAN icon is selected this screen is opened. There are 2 times to set for FAN operation. When the FAN DELAY button is selected, it allows you to adjust the time that the Fan is delayed after the table is UP. Press the set value in the RED Box and use the digital keypad to set a time. When a new time is entered in the keypad press ENT 29

30 Operation - Setup functions for semi automatic use When the FAN RUN TIME button is selected, it allows you to adjust the time that the Fan is activated after the fan delay time. Press the set value in the RED Box and use the digital keypad to set a time. When a new time is entered in the keypad press ENT Set release time When the RELEASE button is selected, it allows you to adjust the time that the release is activated. Press the set value in the RED Box and use the digital keypad to set a time. When a new time is entered in the keypad press ENT.Release times can be set to 0.01 Secs. Set table down time When the TABLE DELAY button is selected, it allows you to adjust the time that the table remains UP after the end of the Vacuum time. Press the set value in the RED Box and use the digital keypad to set a time. When a new time is entered in the keypad press ENT.Table delay times can be set to 0.01 Secs. 30

31 Operation - Setup functions for semi automatic use Save or Exit button When all adjustments are complete press the SAVE OR EXIT button. The following message will prompt to confirm save or exit. Memory screen This grey MEMORY screen will be displayed if you select the SAVE OR EXIT. Select as memory location for the changes. The final parameter review screen opens. The parameter review screen allows final review of the settings. All parameters can be changed at this point. Press on any value and a keypad allows adjustment. The job name may be changed with and keypad. Press save to return to the main menu. 31

32 Operation - Semi-automatic cycle Semi-Automated Cycle With the clamp frame in the up position set the required times for Heater, Prestretch, Vacuum, Fans & Release. Select the semi automatic icon. Select the required job form the list. There are 20 Job Records. SEMI AUTOMATIC OPERATION This screen displays the saved job details including the times for Heating, Vacuum and Fan. The operations of the machine follow the icons in a clockwise direction starting with the heaters in the top left hand corner of the screen. 32

33 Operation - Semi-automatic cycle Clamp the plastic and press the heater button to start the cycle. Once the heater is forward then the time display will count down the heating cycle time. Once the heating cycle is complete the PLC will automatically send the heater back and pre-stretch the plastic if a pre-stretch time has been entered. The operator must at this stage raise the table. When the table has reached the top position then the mould, cooling and release cycles will be performed automatically. At the end of the release cycle the table is sent down by pressing the table down icon on the touch screen. When the table is in the down position press the clamp release button on the control POD and lift the clamping frame. Remove the finished moulding. Other notes on Semi-automatic Operation. Manual intervention of the heating cycle when in Semi-Automatic mode: If the heated plastic becomes ready before the time is complete then press the heater button to send the heater back. As soon as the heater reaches the back position it will continue through to the next stage of the cycle. If more heat is required at the end of the heat time send the heater forwards again to continue heating. Note: 1. This action must be performed before the heater reaches the back position. 2. The heat cycle timer will restart and therefore the heating cycle must be finished manually when the plastic is ready. Manual intervention of the Forming cycle when in Semi-Automatic mode: If manual intervention is required when forming mouldings after the table has been lifted, press the vacuum, fan or release butttons to over-ride the forming cycle and finish the process manually. 33

34 Heater Settings 1372SA - Zone Layout SA Heater element power arrangement Front 400W 300W 300W 300W 300W 300W 300W 300W 300W 300W 400W 300W 250W 250W 250W 250W 250W 250W 250W 250W 250W 300W 300W 250W 250W 250W 250W 250W 250W 250W 250W 250W 300W 300W 250W 250W 250W 250W 250W 250W 250W 250W 250W 300W 400W 300W 300W 300W 300W 300W 300W 300W 300W 300W 400W Element power in Watts Front Heating Zone Control and Adjustment The heating zone control is adjusted by the touch screen. When adjusted this will allow the heat of the corresponding heater zone to be set. Reduce or increase the percentage to each zone to set the required heater power level and review as necessary. See also the section regarding Operating Techniques for heater settings. 34

35 Other Controls and user adjustments Table Speed adjustment TAKE CARE WHEN REACHING TO THE BACK OF THE MACHINE. THERE MAY BE VERY HOT SURFACES IN THIS AREA. ENSURE THAT THE CLAMP FRAME COUNTERWEIGHTS ARE ADJUSTED FULLY FORWARD BEFORE CARRYING OUT THE BELOW PROCEDURE. THIS IS TO PREVENT THE CLAMP SUDDENLY SWINGING UP AND THE COUNTERWEIGHTS DOWN IN THE EVENT OF A PNEUMATIC OR POWER FAILURE. Two table speed adjustments are situated on the lower right hand side of the rear panel. (when viewed from the rear of the machine). These are flow regulators to adjust the air that is exhausted from the table pneumatic cylinder. Inserting a 6mm hexagon key in the centre and rotating clockwise or anti-clockwise will adjust them. Adjust the regulator clockwise to reduce the air exhaust to reduce the cylinder / table speed. Adjust the regulator anti-clockwise to increase the air exhaust to increase the cylinder / table speed. The top flow regulator will adjust the table UP speed. The lower flow regulator will adjust the table DOWN speed. If water accumulates in the plastic reservoir, unscrew the bleed screw to release the water, then tighten up again. Please check this periodically. Clamp speed adjustment - opening Clamp speed adjustment - closing Table up speed adjuster Table down speed adjuster Moisture drain Main air inlet 35

36 Other Controls and user adjustments Table Height Adjustment The lower stop point of the table may be adjusted easily from the outside of the machine. The adjustment is performed by adjusting the table stop shaft situated below the left hand side panel. For convenience the shaft has a 22mm hexagon end. A rotary handle is supplied with the machine to assist with the manual adjustment. Always make adjustments with the table in the raised position. Rotate the handle clockwise to lower the table height. Rotate the handle anti-clockwise to raise the table height. Clamp Frame rear spring adjustment The clamp frame is spring loaded at the rear. The springs are locked in place with 2 M10 nuts. The loading of the springs may need to be adjusted, for example, when using thinner or thicker plastics materials to assist clamping or when a reducing place is fitted. To adjust the spring loading loosen the lower Nut for each spring and adjust the upper nut to suit. Tighten the lower nut to lock against the upper nut. TAKE CARE WHEN REACHING TO THE BACK OF THE MACHINE. THERE MAY BE VERY HOT SURFACES IN THIS AREA. Clamp Frame speed adjustment The clamp speed may be adjusted using the small exhaust flow controls on the clamp valve in the same way as the table speed. 36

37 Other Controls and user adjustments Front clamp limit switch adjustment The front material clamps may need adjustment when reducing plates are fitted. The clamp limit switch is located on the Right hand clamp. This switch is sprung loaded. The switch must be activated to close the clamp. When a reducing plate and plastic is fitted in the aperture the limit switch may not close and the clamp will not operate. To adjust the switch, loosen the 2 nuts retaining the spring loading of the switch so that the switch is positioned lower and is activated when the clamp is lowered. Clamp frame Jacking bars - Front and Rear The clamp frame has jacking bars that can be screwed out to provide a bow in the clamp to assist with clamping. Loosen the bottom screws and tighten the top screws to give better clamping. Adjust to suit the desired profile. Counterweight adjustment - loading and unloading Counterweights are easily adjusted by loosening the screw with a 13mm spanner or socket. ENSURE SCREWS ARE LOCKED TIGHT AFTER ADJUSTMENT. Adjustment is required if, for example, a reducing window is fitted. Adjust the weights so that the clamp frame is balanced. Touch screen control POD position The tilt angle of the touch screen POD is adjustable. Loosen the M5 locking screw on the underside of the pod arm. Set tilt position to suit the height of the operator. Heater motor speed The Heater motor speed may be adjusted. It is set to an optimum factory setting so adjustment is not normally necessary. On occasions where adjustment is necessary this can be performed by adjusting the potentiometer on the heater motor inverter. The speed is shown on the invertor. If this speed is adjusted then it is essential to adjust the positions of the front and rear heater limit switch to suit the drive deceleration position. Deceleration may also be adjusted using the inverter function mode. 37

38 Other Controls and user adjustments Fixing mould tools There are four mould tool fixing points at each corner of the table to accept M6 Screws. Use these to fit full sized mould tool mounting boards, maximum thickness 10mm. Thicker tool mounting may be used if the boards are reduced in size allowing a gap between the board and aperture or if the edges are chamfered. Further holes may be drilled and tapped for M6 thread. Avoid the centre 200mm section along the full left to right length in the centre of the table when positioning mounting points. 38

39 Fault diagnostics/maintenance Before any maintenance work is carried out both electrical and air supplies must be locked in the OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage. That person is responsible for ensuring that the machine is in a safe condition before allowing services to be restored. Electrical The PLC relies on the limit switches continually reporting correct mechanical positioning information. Although extremely robust, limit switches are frequently activated and the operating arm may become loose etc. If a limit switch is not operating properly neither will the PLC operating system. Limit switch faults will stop the auto cycle and may prevent the machine functions completely. A logical approach to detecting the fault begins with an exact appraisal of the fault scenario. Much time can be wasted looking in the wrong areas for a problem that, when found, was obvious. Assessment of the fault will entail understanding which interlocks operate to prevent further actions. Typical fault scenarios Table will not rise. Check that the heater is in the back position and that the heater-back limit switch has been operated. Check that the clamp frame is properly engaged and the limit switch operated. The clamp mechanism will not engage. Check the clamp down limit switches. Is the air turned on? Heater will not come forward. Check that clamp and table are down and the limit switches operated. Autolevel blows the plastic into heater. Check beam sensor alignment. 39

40 Fault diagnostics/maintenance Before any maintenance work is carried out both electrical and air supplies must be locked in the OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage. That person is responsible for ensuring that the machine is in a safe condition before allowing services to be restored. Heater The flexible cable chain between the heaters and the control cabinet contain a number of heatproof power and thermocouple cables. Due to the continual motion of the heater these may eventually suffer from fatigue and require replacement. Only the correct grade of cable should be used, and the work carried out by a skilled technician. The quartz heating elements should be periodically inspected for damage to the quartz elements and to make sure that they are securely mounted and that the electrical connections are tight. For the reasons stated, the elements, associated cables, connectors, fuses and are specifically excluded from our standard warranty. Elements are easily changed, ensure the power is isolated and the air supply is switched off. Remove the screws from the heater cover and remove. Disconnect the faulty element and undo the retaining nuts and lower the element to remove. The fitting of the new element is in reverse. It is recommended that the heater tray electrical connections are periodically checked. This requires the removal of every terminal block cover on the element tray and systematically tightening every terminal screw. This procedure must be performed within the first 6 months of use or sooner if usage is heavy. Repeat this procedure every 12 months thereafter. Replacing a heating element If the plastic is not being heated evenly and there is an obvious cold spot then follow the following procedure. This procedure is simplified if the checks are performed from cold. Switch off machine and let heater cool completely, this will take at least 45 minutes. Bring the heater half way forward, place hand near but not on elements to see if they are still hot. If they are, let machine cool for a further 15 minutes. When elements are completely cool, turn on each zone individually and very carefully feel each element connected to that specific zone. The difference in temperature will quickly become noticeable. If one or more elements fail to heat then follow procedure starting page

41 Fault diagnostics/maintenance Replacing a heating element (continuation) Before any maintenance work is carried out both electrical and air supplies must be locked in the OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage. That person is responsible for ensuring that the machine is in a safe condition before allowing services to be restored. Disconnect the electrical main supply. Bring the heater completely forward. Remove the 6 self tapping screws from the slotted heater cover. Remove completely the heater cover. Remove the cap from the terminal block associated with the faulty element using an 8mm socket. At this stage, check that all element wires and interconnecting wires are fully tightened and that the fault was not merely a loose connection. 41

42 Fault diagnostics/maintenance Replacing a heating element (continuation) Before any maintenance work is carried out both electrical and air supplies must be locked in the OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage. That person is responsible for ensuring that the machine is in a safe condition before allowing services to be restored. Remove the four nuts and washers with a 7mm socket that secure the element to the tray. Each element has two wires, which are connected to the ceramic blocks. Loosen the connector block screws. Position your hand underneath to catch the element as it is released. 42

43 Fault diagnostics/maintenance Replacing a heating element (continuation) Before any maintenance work is carried out both electrical and air supplies must be locked in the OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage. That person is responsible for ensuring that the machine is in a safe condition before allowing services to be restored. By putting your hand underneath, you can identify which element is being replaced. Remove the insulation sleeves. Feed the element wires through the holes in the tray and catch the element. Check the element wattage which is stamped ont the rear, as it can be different from one element to another. 43

44 Fault diagnostics/maintenance Replacing a heating element (continuation) Before any maintenance work is carried out both electrical and air supplies must be locked in the OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage. That person is responsible for ensuring that the machine is in a safe condition before allowing services to be restored. Fitting the new element is a reversal of the previous procedure, except that you have to replace the four nuts and washers of the heating element first and then tighten the connector block screws securely. Replace the heater cover and tighten all 6 screws. 44

45 Fault diagnostics/maintenance Before any maintenance work is carried out both electrical and air supplies must be locked in the OFF position. Only a qualified electrical technician may work on any parts carrying mains voltage. That person is responsible for ensuring that the machine is in a safe condition before allowing services to be restored. Auto-Levelling system ISOLATE COMPRESSED AIR SUPPLY BEFORE ATTEMPTING ANY OF THE BELOW. ALWAYS DISABLE THE TABLE & CLAMP BEFORE ATTEMPTING TO LOCATE OR ADJUST THE OPTICAL SENSOR. This machine is fitted with an automatic sheet levelling system. An optical sensor directs a beam of infrared light across the machine. The system comprises of a transmitter and receiver. If the beam is broken air is pumped into the machine cabinet under the plastic lifting it until beam transmission is re-established. When the plastic is heated it begins to sag and cuts the beam, the compressed air lifts the plastic until it has cleared the beam. The air is then shut off until the plastic sags again. The intervals between the air turning on & off may be very short. The optical sensors are located under the top-frame at the sides. The alignment between the optical sensor and the reflector is finely adjusted. It may require re-adjusting if the machine has been transported or used roughly. If the heater is left for any time over the forming area (without plastic clamped in) sensors may become distorted. The sensor may fail if it is exposed to high temperatures. Adjustment may be carried out by slightly bending the sensor mounting plate. The sensor has two small adjusting screws that alter sensitivity and range. These have been set at the factory and are unlikely to have moved. Only adjust these if you cannot make the sensor work properly by any other means. If no LEDS are visible at any time then the sensor may have lost its power connection or become faulty. The Auto-Level may be working properly but blows the plastic up higher than the top-frame level. If this is the case adjust both sensor mounting plates slightly downward 45

46 Fault diagnostics/maintenance Vacuum Warning: never oil any part of the vacuum pump. It is designed to run dry and could be severely damaged by lubrication. The vacuum circuit requires very little maintenance. The inlet filter is mounted on top of the vacuum pump situated under the table on the RHS of the machine. Unclip the top cover of the filter box. The paper cartridge filter prevents particles and dust from entering the vacuum pump. This filter should be inspected periodically and blown out if dirty or replaced if in poor condition. Do not run the machine without this filter. Worn or damaged seals around the perimeter of the table may cause loss of vacuum. These are consumable parts and require replacement after some time. To replace seals follow the procedure relating of Clamp & Table seals in this section. Other causes of vacuum loss are loose or damaged flexible pipes or fittings, blocked filters or build up of contamination in the vacuum valves. The valves should be dismantled and cleaned with paraffin or diesel fuel. Be sure to remove all traces of the solvent used before re-assembling. Lubricants or other liquid may cause irreparable damage to the pump if introduced into the vacuum circuit. Vacuum system If the vacuum appears to be weak or non-existent check the vacuum gauge: Raise the table up. Take off the four screws that maintain the mould table. Carefully take off the table mould from the machine. This might be a two persons job. Turn on the vacuum. 46

47 Fault diagnostics/maintenance Vacuum system (continuation) Place the palm of your hand on top of the vacuum hole. Check the reading on your vacuum gauge. If the vacuum gauge reads 25 or higher, that is normal. A lower reading indicates poor vacuum where attention is required. If the vacuum gauge reading is below 25, check the following: The mould baseboard is not restricting the vacuum inlet in the drape table. NOTE: If the mould baseboard is too soft it may pull down under vacuum and block the vacuum inlet. The mould is adequately vented to allow trapped air to be evacuated. The table and clamp seals are in good order and the table is locking properly at the top of its travel. There are no open holes in the drape table. The filter box cover is correctly fitted. The vacuum valve is operated by a pilot valve using compressed air, this may not operate if the pressure is too low. If all the above points are OK and you can hear the pump running when you switch it on then one of the following points will be the cause of the problem. If the pump does not run, refer to the Electrical trouble shooting section above. A pipe is loose, damaged or blocked. The pump filter is blocked. The vacuum valve is blocked or corroded. The vacuum pump is blocked or corroded. If the heater has been left in the forward position, with no plastic in the clamp frame, the table will start to overheat. The pipe attached to the back of the table will shrink and constrict the passage of air. Pipes become less flexible over time and may loosen or crack. 47